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IA
International Automotive Components
Senior Controls Engineer
Career Insights for Manufacturing Automation Engineer
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Based on Michigan data
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What they do
A Manufacturing Automation Engineer designs, programs and improves automated machinery and processes within a manufacturing environment. Are responsible for the design specifications, documentation and troubleshooting of the equipment. Often work within vehicle manufacturing and food processing plants, where robots or machines are used to perform specific functions.
$107,654 / year median in Michigan
+6% projected growth
Job Description
Position Summary The Senior Controls Engineer is responsible for the design, development, implementation, and optimization of manufacturing control systems and automation solutions supporting automotive production operations. This role leads capital equipment projects from concept through launch, ensuring processes meet safety, quality, productivity, scrap, and labor objectives. The Senior Controls Engineer serves as a technical expert in PLC programming, robotics integration, process controls, and continuous improvement initiatives. This position also supports new product launches, equipment upgrades, troubleshooting, and plant automation strategies. This scope aligns with the existing IAC role description, which includes managing capital equipment processes, establishing controls, documenting processes, participating in PFMEA activities, and leading continuous improvement efforts. Essential Responsibilities Lead the design, programming, commissioning, and validation of automated manufacturing equipment and control systems. Develop and modify PLC, HMI, servo, vision, and robotic control programs. Support new program launches by ensuring all controls systems meet project timing, quality, and production requirements. Establish process parameters, equipment controls, and monitoring systems to maintain product quality and operational performance. Troubleshoot and resolve electrical, controls, automation, and process-related issues. Collaborate with manufacturing, quality, maintenance, product engineering, and suppliers to improve equipment performance and process capability. Lead root cause analysis and corrective actions for equipment downtime and quality concerns. Develop and maintain controls documentation including: Electrical schematics Network architecture PLC/HMI backups Process control plans Equipment standards Participate in PFMEA and manufacturing feasibility reviews. Support capital equipment sourcing, installation, validation, and startup activities. Train maintenance and production personnel on equipment operation, troubleshooting, and preventive maintenance. Drive continuous improvement initiatives focused on: OEE improvement Scrap reduction Cycle-time reduction Cost savings Automation expansion Ensure compliance with all safety, environmental, and customer requirements. Education Bachelor's Degree in Electrical Engineering, Controls Engineering, Mechatronics Engineering, or related technical field. Experience 7-10 years of controls engineering experience in a manufacturing environment. Automotive Tier 1 supplier experience strongly preferred. Experience supporting automated assembly, injection molding, foam, or interior trim manufacturing processes preferred.