Automation Engineer

Frey Consulting Group; Kalamazoo (MI); On-site; USD 90,000 - 120,000; Full time

Job summary

Frey Consulting Group in Kalamazoo, MI seeks a hands-on Controls Engineer to design, implement, and optimize automation and machine vision systems across a highly automated manufacturing operation. You will lead reliability and continuous improvement initiatives with operations and maintenance teams.

The role requires 5+ years in controls/automation, strong PLC/HMI experience, and a proactive problem-solving approach in a fast-paced plant environment. Excellent growth opportunities available.

Qualifications

• Associate degree in Electrical Engineering Technology, Electrical Engineering, Automation, Mechatronics, or related field with manufacturing experience.
• Bachelor's degree in Electrical Engineering or related discipline preferred.
• 5+ years of controls engineering or automation experience in manufacturing.
• Strong hands‑on experience with Allen‑Bradley ControlLogix/Studio 5000 PLCs and automation systems.
• Experience supporting automated equipment and industrial electrical systems.

Responsibilities

• Design, develop, and implement automation and machine vision systems to improve quality and efficiency.
• Provide technical support and troubleshooting for production equipment and automated systems.
• Lead reliability and continuous improvement initiatives focused on safety, quality, productivity, and cost reduction.
• Program, troubleshoot, and optimize Allen‑Bradley PLCs, HMIs, and motor drive systems.
• Support industrial electrical systems and automation infrastructure across the facility.
• Work independently on automation and controls projects from concept through implementation.
• Collaborate with maintenance, engineering, and production teams to resolve issues.
• Analyze equipment performance and identify opportunities to improve reliability and reduce waste.
• Mentor maintenance and operations personnel on equipment functionality and best practices.
• Participate in Lean Manufacturing and Six Sigma improvement projects.

Skills

Allen-Bradley PLCs

HMIs

Industrial automation

Troubleshooting

Lean Six Sigma

Education

Associate degree in Electrical Eng Tech / related field

Bachelor's degree in Electrical Engineering or related field (preferred)

Tools

Studio 5000

EtherNet/IP

Job description

Controls Engineer – Industrial Manufacturing

We are seeking a Controls Engineer to join a highly automated manufacturing operation in the Kalamazoo, MI area. This role is responsible for optimizing manufacturing equipment and processes through automation, process controls, and machine vision technologies while leading reliability and continuous improvement initiatives throughout the facility.

This is an excellent opportunity for a hands‑on controls professional who enjoys solving complex technical challenges, improving manufacturing performance, and working closely with operations and maintenance teams.

Primary Responsibilities

• Design, develop, and implement automation and machine vision systems to improve quality, reduce errors, and increase manufacturing efficiency.
• Provide technical support and troubleshooting for production equipment and automated systems.
• Lead reliability and continuous improvement initiatives focused on safety, quality, productivity, and cost reduction.
• Program, troubleshoot, and optimize Allen‑Bradley PLCs, HMIs, and motor drive systems.
• Support industrial electrical systems and automation infrastructure throughout the facility.
• Work independently on automation and controls projects from concept through implementation, including hands‑on field work.
• Collaborate with maintenance, engineering, and production teams to resolve equipment and process issues.
• Analyze equipment performance and identify opportunities to improve reliability and eliminate waste.
• Mentor maintenance and operations personnel on equipment functionality and best practices.
• Participate in and lead Lean Manufacturing and Six Sigma improvement projects.
• Document engineering changes, programming updates, and technical solutions.
• Support plant safety initiatives and ensure automation systems comply with applicable safety standards.

Qualifications

• Associate degree in Electrical Engineering Technology, Electrical Engineering, Automation, Mechatronics, or a related technical field with equivalent manufacturing experience required.
• Bachelor's degree in Electrical Engineering or a related engineering discipline preferred.
• Five (5)+ years of controls engineering or automation experience within a manufacturing environment.
• Strong hands‑on experience with:
• Allen‑Bradley ControlLogix/Studio 5000 PLCs
• Experience supporting highly automated manufacturing equipment and industrial electrical systems.
• Strong troubleshooting skills involving PLCs, drives, HMIs, sensors, and production equipment.

Preferred Skills

• Machine vision/visual inspection systems
• Robotics integration and troubleshooting
• Industrial networking (EtherNet/IP and related industrial communication protocols)
• Process improvement, Lean Manufacturing, and Six Sigma experience
• Root cause analysis and reliability engineering
• Project management experience leading automation or capital improvement projects

Desired Competencies

• Excellent analytical and problem‑solving skills.
• Strong verbal and written communication abilities.
• Ability to manage multiple priorities in a fast‑paced manufacturing environment.
• Self‑motivated with the ability to work independently while collaborating effectively across departments.
• Proficiency with Microsoft Office applications, including Excel, Word, and PowerPoint.
• Comfortable working around heavy industrial manufacturing equipment and furnaces.

Why Consider This Opportunity?

• Join a highly automated manufacturing facility investing in technology and continuous improvement.
• Lead impactful automation and reliability projects with visible results.
• Work alongside experienced operations, maintenance, and engineering professionals.
• Competitive compensation, comprehensive benefits, and opportunities for professional growth and advancement.