Advanced Controls Process Engineer

LuxWall, Inc.; Litchfield Township (MI); On-site; USD 80,000 - 110,000; Full time

Benefits offered by this job

Medical insurance

Vision insurance

401(k)

Paid maternity leave

Paid paternity leave

Disability insurance

Job summary

A technology-driven company in Michigan is seeking an Advanced Controls Process Engineer for a full-time role. The ideal candidate will have over 7 years of PLC programming experience and be responsible for optimizing production processes and integrating automation systems. This role requires a strong analytical mindset and problem-solving skills in a fast-paced manufacturing environment. The company offers competitive benefits, including medical insurance and a 401(k) plan.

Qualifications

• 7+ years of hands-on PLC programming experience required.
• Comfortable in a fast-paced manufacturing environment.
• Experience with vacuum systems or robotics is a plus.

Responsibilities

• Analyze and optimize production processes for efficiency.
• Develop and modify PLC programs to improve performance.
• Lead troubleshooting of PLCs and automation systems.

Skills

PLC programming

Robotics

Troubleshooting

Automation system design

Data analysis

Education

Bachelor’s degree in electrical engineering or related fields

Tools

Allen-Bradley PLCs

Siemens PLCs

EPLAN

AutoCAD

Job description

1 day ago Be among the first 25 applicants

LuxWall is focused on the product development, scaling, and commercializing of innovative Transparent Insulation products and solutions for the built environment. LuxWall’s vacuum insulated technology, Enthermal™, delivers a step change in energy performance, eliminating convective heat transfer and drastically reducing conductive and radiant heat gain and loss within buildings. The result is up to 45% in energy savings, while improving comfort and noise reduction. LuxWall has the potential to redefine building performance globally and forever change the way buildings are designed and constructed.

Job Overview

The Advanced Controls Process Engineer will play a critical role in analyzing, designing, and optimizing production processes to enhance efficiency, reduce waste, and improve product quality to LuxWall’s production manufacturing lines. This position requires PLC (ladder logic)/Robotics experience, strong analytical mindset, attention to detail, and a passion for problem‑solving.

Position Responsibilities

PLC and Automation Programming

• Develop ladder logic and structured text programs from scratch for new manufacturing equipment, automated transfer systems, robotics, and quality control devices.
• Modify and optimize existing PLC programs to improve cycle time, reduce downtime, and maximize throughput.
• Implement robust monitoring, fault detection, interlocks, and recovery routines.
• Demonstrated ability to implement structured logic for maintainability
• Develop and optimize motion control and servo tuning on continuous production lines.

Hardware and PLC Integration

• Integrate and commission a wide range of sensors and automation hardware including:
• Photo-eyes and light curtains
• Pyrometers and thermal sensors
• Linear encoders, proximity sensors, load cells
• Pneumatic and electromechanical actuators
• Develop and implement I/O maps, sourcing/sinking, signal types, communications protocols, and device configuration (Ethernet/IP, Modbus, ProfiNet, etc.).

Automation System Design and Troubleshooting

• Lead debugging, diagnostics, and troubleshooting of PLCs, HMIs, robotics, motion systems, and safety systems.
• Conduct root‑cause analysis for faults, downtime, and system variability.
• Understand wait conditions, unnecessary interlocks, and redundant scans to improve cycle time.
• Support equipment start‑up, functional acceptance tests, process acceptance tests, final commissioning, and integration into manufacturing workflow.
• Partner with mechanical, electrical, and process engineering teams to bring highly engineered equipment online.

Manufacturing Performance Optimization

• Analyze automated processes to identify bottlenecks, inefficiencies, and opportunities for throughput improvement.
• Collaborate with operations, process engineering, and maintenance to implement logic changes and equipment upgrades.
• Support continuous improvement (Lean/6σ) initiatives for uptime, quality, and cycle time.

Documentation, Standards and Training

• Create and maintain electrical schematics, functional design specifications (FDS), PLC/HMI code documentation, and change logs.
• Develop and enforce LuxWall automation standards for controls architecture, PLC hardware, nomenclature, and logic conventions.
• Support supplier equipment integration and ensure alignment with LuxWall controls standards.
• Train maintenance technicians and production teams on new systems and upgrades.

Qualifications

• Bachelor’s degree in electrical engineering, controls engineering, automation, mechatronics, software engineering, or equivalent degree(s).
• 7+ years of hands‑on PLC programming experience, including ladder logic and structured text.
• Demonstrated ability to write ladder logic from the ground up for new automation systems.
• Experience integrating photo‑eyes, pyrometers, cameras, motion systems, and other sensors.
• Strong troubleshooting skills for electrical, PLC, and automation systems.
• Experience with Allen‑Bradley/Rockwell Automation and/or Siemens (preferred) PLCs.
• Ability to read and interpret electrical schematics (EPLAN/AutoCAD).
• Knowledge working with SCADA, MES, data acquisition, and industrial networking.
• Self‑starter with strong ownership, urgency, and hands‑on problem‑solving capability.
• Comfortable in a fast‑paced manufacturing environment with evolving needs.
• Experience commissioning custom‑built equipment on greenfield production lines.
• Experience with vacuum systems, thermal processes, or glass manufacturing is preferred.
• Experience with robotics (Fanuc, Kuka, ABB, Kawasaki) a strong plus.
• Requires working in a fast‑paced manufacturing environment with exposure to machinery, chemicals, and varying temperatures and noise levels.
• Constant communication with employees, peers and management
• Overtime as required
• Frequent requirement of handling heavy equipment (operation)
• Frequent need to give concentrated attention to surroundings

LuxWall, Inc. is an Equal Opportunity Employer. We do not discriminate based on race, color, religion, sex, sexual orientation, gender identity, national origin, disability, age, veteran status, or any other legally protected characteristics. All employment decisions are based on qualifications, merit, and business needs.

All applicants must complete and pass a drug screening and background check. LuxWall's process is a 10-panel drug screen which includes marijuana.

Seniority level

Mid‑Senior level

Employment type

Full‑time

Job function

Wholesale Building Materials, Glass, Ceramics and Concrete Manufacturing, and Glass Product Manufacturing

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Medical insurance

Vision insurance

401(k)

Paid maternity leave

Paid paternity leave

Disability insurance