Controls Engineer

Cummins Inc.; Maxton (NC); On-site; USD 85,000 - 105,000; Full time

Job summary

Cummins Inc. in Maxton, NC is seeking a talented Controls Engineer for its Manufacturing unit. You will develop control systems, program PLCs and HMIs, and work across teams to optimize equipment performance and process stability.

You will drive validation, troubleshooting, and integration of automation solutions, while mentoring junior engineers and ensuring safety and quality in all activities. This role is on-site at Cummins Drivetrain and Braking Systems in Maxton.

Qualifications

• Must have a STEM degree or equivalent experience.
• This position may require licensing for export controls or sanctions regulations.

Responsibilities

• Drive operational excellence by designing reliable control systems and improving equipment performance.
• Conduct bench tests to validate control logic and hardware per engineering specs.
• Troubleshoot and resolve complex system issues to minimize downtime and risk.
• Collaborate across functions to support manufacturing capabilities and project budgets.

Skills

Control systems

PLC programming

HMI programming

Troubleshooting

Data-driven decisions

Collaboration

Education

STEM degree

Export controls licensing

Tools

AutoCAD

Ignition OPC

Kepware OPC

Apriso MES

Allen-Bradley PLC

MS Office

Job description

Job Summary:

We are looking for a talented Controls Engineer to join our team specializing in Manufacturing for our Cummins Drivetrain and Breaking Systems Business Unit facility in Maxton, NC

The Controls engineer develops all aspects of control systems, equipment, and machinery.

In this role, you will make an impact in the following ways:

• Drive operational excellence by developing and designing reliable control systems that improve equipment performance, efficiency, and overall process stability.

• Ensure system integrity by creating and executing bench tests that validate control logic, hardware functionality, and compliance with engineering specifications.

• Optimize automation performance by modifying software and equipment configurations to ensure sensors, actuators, and control devices operate accurately and efficiently.

• Resolve complex technical challenges by troubleshooting, debugging, and implementing effective solutions for system issues and change requests, minimizing downtime and risk.

• Support sound business decisions by preparing accurate cost estimates, compiling equipment requirements, and contributing to well-justified appropriation requests.

• Deliver innovative, practical solutions by analyzing project requirements and developing plans that balance technical, economic, personnel, and environmental considerations.

• Strengthen manufacturing and operational capabilities through the installation, programming, and technical support of PLC-based hardware and software systems.

• Build team capability and future talent by coaching and mentoring less experienced Controls Engineers, sharing technical expertise, and fostering continuous learning and development.

To be successful in this role you will need the following:

• Build strong partnerships and collaborate effectively by working across functions, engineering teams, operations, maintenance, and suppliers to achieve shared project and business objectives.

• Communicate clearly and influence stakeholders by translating complex technical concepts into understandable information for operators, technicians, leaders, and engineering teams.

• Champion health and safety every day by proactively identifying risks, following safe work practices, and fostering a culture where safety is integrated into all controls engineering activities.

• Develop deep controls engineering expertise by applying knowledge of controls hardware and software to design, review, implement, and improve manufacturing equipment and systems.

• Leverage controls networking and system integration by connecting machines, processes, and databases to improve automation, data visibility, production performance, and decision-making.

• Prioritize controls safety and cybersecurity by incorporating electrical, hydraulic, and pneumatic safety principles while ensuring manufacturing control systems are protected from security risks and vulnerabilities.

• Master troubleshooting and automation technologies by diagnosing electrical control system issues, resolving complex problems efficiently, and implementing automation solutions that improve reliability, quality, and productivity.

• Apply manufacturing knowledge, machine programming, and sensor technologies to optimize processes, enhance equipment performance, improve product quality, support continuous improvement initiatives, and drive operational excellence.

• Use data and measurement-driven decision making by analyzing sensor data, validating system performance, identifying root causes, and implementing solutions based on factual insights.

• Value diverse perspectives and continuous learning by embracing different viewpoints, sharing knowledge, mentoring others, and staying current with emerging automation, controls, and manufacturing technologies.

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:

• Intermediate level of relevant work experience required.

Additional Preferred Experience and Responsibilities:

• Complete knowledge of low power DC control systems (+24 VDC, +12 VDC) and high voltage power distribution systems when it applies to equipment and machinery (480 VAC)

• Proficient at reading machine and assembly line electrical prints

• Proficient at creating and modifying electrical prints

• Strong troubleshooting skills related to machines and assembly lines (i.e. control systems, motors, drives, relay controls, sensors, valves, actuators etc…)

• Strong troubleshooting and debug skills related to PLC programs

• Able to design complete control systems required for plant assembly lines

• Able to do electrical enclosure/panel design for plant assembly lines and poka yoke systems

• Able to wire electrical enclosures and panels based on control system designs

• Fluency in Allen Bradley HMI and RedLion HMI programming

• Ability to configure Allen Bradley controls hardware and third part controls hardware out-of-the-box for ethernet IP communications

• Complete understanding of industrial networks and the ability to develop control systems networks

• Understanding of MES systems and the ability to learn our Apriso MES system to become a super user

• Ability to launch full MES solutions with our Apriso MES system to be able to integrate with our machines and assembly lines

• Fluency with Kepware OPC (i.e. mapping of both PLC layer tags and Apriso MES MI points)

• Fluency with Ignition OPC (i.e. mapping of both PLC layer tags and Apriso MES MI points)

• Ability to learn Ignition Vision Client development

• Understanding and willingness to learn JSON payload scripting for AGV interfacing adhering to the VDA5050 AGV standard for AGV communications

• Understanding of torque controllers so that they can be integrated into controls systems

• Understanding of vision systems so that existing vision system applications can be supported and maintained but also so that new vision systems can be integrated into control systems

• Understanding of safety systems and how these tie into machine and assembly line control systems

• Understanding of End-of-Line test equipment with the ability to expand both hardware and software on such systems

• Team oriented and able to work under pressure in a manufacturing environment

• Creative thinker, team player that works well with others who brings a positive attitude

• Support plant maintenance team during machine/equipment troubleshooting needs

• Able to teach plant maintenance team new systems, plc code and hmi code

• Ability to travel for equipment/machine runoffs

• Ability to work at other Cummins sites if required

• Expert use of AutoCad is a must

• Expert use of all MS Office software package is a must

• Strong mechanical aptitude

Job Manufacturing

Organization Cummins Inc.

Role Category On-site with Flexibility

Job Type Exempt - Experienced

ReqID 2431937

Relocation Package Yes

100% On-Site No

Cummins and E-Verify

At Cummins, we are an equal opportunity and affirmative action employer dedicated to diversity in the workplace. Our policy is to provide equal employment opportunities to all qualified persons without regard to race, gender, color, disability, national origin, age, religion, union affiliation, sexual orientation, veteran status, citizenship, gender identity and/or expression, or other status protected by law. Cummins validates the right to work using E-Verify and will provide the Social Security Administration (SSA) and, if necessary, the Department of Homeland Security (DHS), with information from each new employee7s Form I-9 to confirm work authorization. Visit http://EEOC.gov to know your rights on workplace discrimination.