Electrician - Level II
Cummins Inc
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Job summary
The Controls Engineer at Cummins Inc. provides electrical maintenance and automation support to manufacturing equipment, including PLC programming, robotics integration, and control system development.
You will troubleshoot, commission, and optimize systems, working with cross-functional teams to meet safety, quality, and productivity targets. You will lead maintenance activities, drive TPM initiatives, and support Industry 4.0 efforts while adapting to shift-based manufacturing needs.
Qualifications
- 3–5 years of hands-on mechatronics maintenance experience with PLCs and assembly line machines.
- Siemens S7-1500 PLCs experience and robotics programming.
- HMI/SCADA development knowledge.
- Strong troubleshooting and adherence to safety standards.
Responsibilities
- Support electrical maintenance and automation for manufacturing equipment.
- Develop, troubleshoot, and optimize PLC programs, robot logic, and HMI/SCADA applications.
- Lead maintenance and automation activities with cross-functional teams to improve uptime and safety.
- Coordinate with production to plan preventive and corrective maintenance.
- Ensure compliance with safety standards and continuous improvement initiatives.
Skills
Education
Tools
Job description
Performs electrical maintenance and machine support tasks to keep equipment available and capable. Selects and uses appropriate tools, machinery and specialty equipment completing work with limited guidance. Learns and understand the protocols of working safely with electricity and other energy sources with industrial equipment.
Health, Safety & Environmental (HSE)Stop work and immediately report any major injury hazards.Report any work-related injury, illness, incident or hazard.Comply with HSE standards, policies, procedures and regulations.Use appropriate personal protective equipment.Promote interdependence by looking out for one another.Correct hazards within your control and capabilities.Recognize how your work may impact the environment and work to minimize the negative impact.Engage in HSE Training.QualityApplies high standards of workmanship and craftsmanship.Support equipment uptime and downtime failure analysis.Performs work in accordance with diagrams, sketches, operation manuals and specifications using various tools, measuring and testing instruments.Provide feedback into the Preventive Maintenance system.Follows all process documentation and quality procedures.Raises issues to minimize cost and quality exposures.Performs quality inspections.DeliveryPerforms electrical repairs and maintenance of manufacturing equipment .Demonstrates a high level of competency in core work skills.Performs and documents preventive, emergency, corrective and predictive maintenance activities.Conforms to applicable codes and standards to maintain, install, and operate electrical systems.Maintains clean and orderly work area, including routine housekeeping and machine cleaning tasks.Performs other duties as required to meet business goals.Identify and reduce manufacturing constraintsSchedule maintenance activities around production requirementsSolve problems and improve processesParticipate in continuous improvement activitiesTeamworkCommunicates effectively with the assigned team and with all support teams.Completes training and personal development in line with business requirements.Participates actively with local Total Productive Maintenance (TPM) teams in ways to improve quality, safety, process, material flow, and employee development.
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.
Customer focus - Building strong customer relationships and delivering customer-centric solutions.
Decision quality - Making good and timely decisions that keep the organization moving forward.
Drives results - Consistently achieving results, even under tough circumstances.
Nimble learning - Actively learning through experimentation when tackling new problems, using both successes and failures as learning fodder.
Health and Safety Fundamentals - Champions and models proactive health and safety behaviors 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 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.
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.
Machine Programming - Creates factory floor machine programs by designing and implementing solutions to improve usage of machine and overall operation.
Manufacturing Knowledge - Demonstrates the knowledge of manufacturing by correctly implementing changes in current processes, equipment, and applications to meet the function's needs and contribute towards continuous improvement.
Values differences - Recognizing the value that different perspectives and cultures bring to an organization.
High school diploma or certificate of completion of secondary education or equivalent experience to the extent such experience meets applicable regulations.
This position may require licensing for compliance with export controls or sanctions regulations.
Requires some work experience or intermediate level knowledge obtained through education, training or on-the-job experience.
The Controls Engineer is responsible for supporting and improving manufacturing automation systems to achieve safety, quality, delivery, and cost objectives. This role provides electrical maintenance and automation support through PLC programming, robotics integration, control system development, troubleshooting, commissioning, and process optimization. Working closely with cross-functional teams, the Controls Engineer ensures reliable and efficient operation of production equipment, drives continuous improvement initiatives, and maintains compliance with safety, quality, and operational standards. The position requires the ability to work independently with limited supervision and flexibility to support shift-based manufacturing operations as needed.
Ensure compliance with Cummins Health, Safety, Environmental (HSE), quality, and manufacturing standards.
Enforce Lockout/Tagout (LOTO), Permit to Work systems, machine safety requirements, PPE compliance, and safety PLC standards.
Conduct risk assessments, safety audits, and machine safety validations, including interlocks, emergency circuits, and guarding systems.
Promote 5S, housekeeping, and continuous improvement practices to maintain a safe and efficient work environment.
Develop, modify, troubleshoot, and optimize PLC programs, robot logic, HMI/SCADA applications, and automation control systems.
Design and implement end-to-end automation solutions, including control philosophy, sequence logic, and safety architecture for manufacturing equipment and production lines.
Program, configure, and support Siemens S7-1500 PLCs, ABB, FANUC, and Yaskawa robotic systems.
Integrate robots, vision systems, conveyors, manipulators, servo drives, VFDs, safety PLCs, sensors, and other automation devices.
Configure and maintain industrial communication networks such as Profinet, Ethernet/IP, Modbus.
Develop standardized control architectures, reusable software modules, and automation best practices.
Support Industry 4.0, machine connectivity, predictive maintenance, cybersecurity, and digital manufacturing initiatives.
Lead installation, commissioning, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and production ramp-up activities.
Troubleshoot complex automation, electrical, robotics, hydraulic, and pneumatic system issues to minimize downtime and improve equipment reliability.
Drive preventive, predictive, and corrective maintenance programs using CMMS systems such as MAXIMO.
Conduct Root Cause Analysis using structured methodologies (5 Why, Fishbone, FTA) and implement sustainable corrective actions.
Monitor and improve equipment performance through OEE, MTBF, MTTR, cycle time, throughput, and reliability improvements.
Coordinate maintenance and automation activities with production, quality, suppliers, and OEMs to support manufacturing objectives.
Identify and implement process optimization opportunities to improve productivity, quality, safety, and cost performance.
Support capital projects through technical evaluation, cost estimation, appropriation requests, equipment specifications, and project execution.
Lead cost reduction initiatives focused on maintenance efficiency, energy conservation, spare optimization, and waste elimination.
Prepare technical documentation, engineering reports, control narratives, project plans, and operating procedures.
Provide technical leadership and hands-on support to technicians, trainees, and junior engineers across shifts.
Coach, mentor, and develop team members to strengthen controls, automation, and troubleshooting capabilities.
Lead shift meetings and maintenance reviews to communicate safety requirements, production priorities, and operational targets.
Manage contractors and service providers to ensure work is completed safely, efficiently, and in compliance with company standards.
Plan and manage critical spare parts inventory to support automation system reliability and business continuity.
Track maintenance and automation performance metrics, ensuring achievement of uptime, reliability, quality, and cost objectives.
Support resource planning and budgeting activities while driving continuous improvement in maintenance and automation performance
Work in rotational shifts as per operational and business requirements.
- High school diploma or certificate of completion of secondary education, or equivalent experience as permitted by applicable regulations.
Experience in automotive, manufacturing, industrial automation, or robotics environments.
Siemens S7-1500 PLC programming and troubleshooting.
Robotics programming, teaching, commissioning, and troubleshooting (ABB, FANUC, Yaskawa).
HMI and SCADA development and support.
Automation and control system integration.
Industrial networking technologies including Profinet, Ethernet/IP, Modbus, and OPC UA.
Servo drives, VFDs, sensors, actuators, motion control, and control system hardware.
PLC programming languages including Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
Advanced troubleshooting of electrical and automation systems.
Machine safety systems, Safety PLCs, LOTO, and industrial safety standards.
Controls system cybersecurity and network architecture.
Manufacturing process automation and continuous improvement methodologies.
Certifications or specialized training in PLC programming, robotics, SCADA, or industrial automation.
3-5 years of hands-on Mechatronics maintenance experience, specifically with PLC’s and Assembly line machines.
Siemens S7-1500 PLC programming and troubleshooting.
Robotics programming, teaching, commissioning, and troubleshooting (ABB, FANUC, Yaskawa).
HMI and SCADA development and support.
Automation and control system integration.
Industrial networking technologies including Profinet, Ethernet/IP, Modbus, and OPC UA.
Servo drives, VFDs, sensors, actuators, motion control, and control system hardware.
PLC programming languages including Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
Advanced troubleshooting of electrical and automation systems.
Machine safety systems, Safety PLCs, LOTO, and industrial safety standards.
Controls system cybersecurity and network architecture.
Manufacturing process automation and continuous improvement methodologies.
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