Controls Engineer

Cummins; Pune District, Satara; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Cummins in Pune, India is seeking a Controls Engineer to assist the development of control systems, equipment, and machinery.

You will design and implement bench tests, adjust software and hardware, and support RCA investigations while coordinating with experienced engineers.

The role emphasizes safety, 5S housekeeping, and reliability, with opportunities to work across shifts on production equipment.

Qualifications

• Basic level of relevant experience.
• College or university degree in STEM or related field.
• Export controls or sanctions licensing may be required.

Responsibilities

• Assist design and development of control systems and bench tests.
• Alter software and hardware to ensure sensors and actuators meet specifications.
• Prepare cost estimates and draft appropriation requests.
• Investigate problems and plan solutions with experienced engineers or manager.
• Install and provide technical support of PLC-based hardware and software.

Skills

Controls Engineering Knowledge

Factory Automation

Sensor Technology

Electrical System Troubleshooting

Machine Programming

Siemens PLC

Mitsubishi PLCs

MAXIMO

Education

STEM degree or equivalent

Tools

MAXIMO

Siemens PLCs

Mitsubishi PLCs

Job description

Job Summary

Assists with the development of all aspects of control systems, equipment, and machinery.

Key Responsibilities

Assists with the development and design of control systems; assists with the development and implementation of bench tests; alters software and equipment to ensure that sensors and actuators are functioning according to specifications; supports and debugs basic problems and change requests. Assists with the preparation of cost estimates; compiles required cost and equipment information, and drafts appropriation requests. Investigates problems and requirements of projects, and develops plans for solutions in line with economic, personnel, and environmental considerations for review by more experienced Controls Engineers or Controls Engineering Manager. May be responsible for the installation and technical support of Programmable Logic Controller (PLC) based hardware and software.

Safety Environment (EHS)

• Enforce Safety Rules: Ensure 100% compliance with Lockout/Tagout (LOTO), Permit to Work, and PPE requirements.
• Assess Risk: Perform regular safety audits and risk assessments to keep the machine shop safe and "audit-ready" at all times.
• Maintain 5S Standards: Lead housekeeping and 5S initiatives to keep the shop and tool rooms organized and efficient.

Team Leadership Supervision

• Manage the Team: Direct daily activities for technicians and trainees; assign tasks, manage schedules across all 3 shifts, and resolve team issues.
• Drive Discipline: Set clear expectations for workplace behaviour and ensure the team follows company policies.
• Coach Develop: Guide staff to hit their individual goals and provide regular feedback on their progress.
• Communicate Clearly: Lead shift meetings to update the team on production priorities, safety goals, and maintenance targets.

Machine Reliability Operations

• Keep Production Running: Handle daily breakdowns in the machine shop to hit "uptime" targets (MTBF and MTTR).
• Root Cause: Lead investigations (RCA) into why machines fail and fix the underlying problem so it doesnt happen again.
• Manage Work Orders: Use the MAXIMO system to track all repairs (Emergency, Preventive, and Predictive) and keep accurate machine histories.
• Coordinate Downtime: Work closely with Production Supervisors to schedule machine maintenance at times that wont hurt production output.
• Oversee the maintenance and calibration of high-precision assembly stations.
• Vision System Optimization: Supervise the fine-tuning and maintenance of automated optical inspection.

Technical Expertise (Hands‑on)

• Expert Troubleshooting: Provide hands‑on repair support for Assembly line machines, Robots, Conveyors, Nut Runners EOL Testing Equipments.
• Control Systems: Use your experience with SIEMENS, Mitsubishi controllers/PLCs to fix complex issues.
• Systems Knowledge: Troubleshoot and maintain Hydraulic, Pneumatic, and automated material handling systems.

Planning Cost Control

• Spare Parts Management: Plan and track spare parts inventory (using tools like VED analysis) to ensure we have what we need without overspending.
• Cost Saving: Identify and lead projects to reduce energy use, lower maintenance expenses, and cut waste.
• Manage Contractors: Oversee external service providers to make sure their work is high‑quality and meets our safety standards.

Competencies

• Collaborates - Building partnerships and working collaboratively with others to meet shared objectives.
• Communicates effectively - Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences.
• Health and Safety Fundamentals - Champions and models proactive health and safety behaviours by identifying, reporting and participating in actions to improve health and safety in order to build an interdependent culture and contribute to an injury‑free workplace.
• Controls Engineering Knowledge - Applies the application of controls hardware and software by specifying, reviewing, and approving company‑owned and/or supplier designs for new or upgrades to existing equipment to interface with all levels of manufacturing systems.
• Controls Networking - Implements new and improved technologies and methods capable of transferring information from multiple inputs either within a local production process or into databases to link machines together or to analyze the process for overall operation enhancements.
• Controls Safety - Recognizes controls related hazards in a manufacturing environment (Electrical, Hydraulic, Pneumatic) to incorporate safe practices and procedures as part of the daily work plan to reduce injuries and create a safe machine environment.
• Controls System Security - Develops and implements Controls System Security by specifying, reviewing, and approving company‑owned and/or supplier designs for new equipment or upgrades to existing equipment to ensure our manufacturing controls and systems are secure.
• Electrical System Troubleshooting - Analyzes an electrical control system to resolve and repair electrical issues to return the system to proper operating conditions.
• Factory Automation and Control Systems - Implements changes to further automate manufacturing processes using available technology, programming techniques, and identifying needed material and resources for project completion to provide the optimum automation for the manufacturing environment.
• Sensor Technology and Measurement - Selects and applies the sensor technology, performing measurements in the acquired data that leads to the correct analysis and conclusion to help differentiate products that meet quality standards from non‑conforming products.
• Values differences - Recognizing the value that different perspectives and cultures bring to an organization.
• Manufacturing Knowledge - Demonstrates the knowledge of manufacturing by correctly implementing changes in current processes, equipment, and applications to meet the functions needs and contribute towards continuous improvement.
• Machine Programming - Creates factory floor machine programs by designing and implementing solutions to improve usage of machine and overall operation.

Education, Licenses, Certifications

College, university, or degree in STEM (Science, Technology, Engineering, Math) or related field, or equivalent experience required.

This position may require licensing for compliance with export controls or sanctions regulations.

Experience

Basic level of relevant experience required.

Disclaimer: This job posting has been aggregated from external source. Role details, content, and availability are subject to change. Applicants are advised to confirm the latest information directly on the company website before applying.