Controls Engineer

Troy Design and Manufacturing - A wholly owned Ford Motor Company subsidiary; Shelbyville (KY); On-site; USD 70,000 - 100,000; Full time

Job summary

Troy Design and Manufacturing - A wholly owned Ford Motor Company subsidiary in Shelbyville, KY, seeks a Controls Engineer for Die Casting. You will design, program, and maintain control systems for die casting machines and related automation, including PLCs, HMIs, robots, conveyors, and cooling systems.

The role involves optimizing cycle times, reducing waste, improving quality, and collaborating with mechanical, electrical, and process engineers to ensure seamless integration with equipment.

Qualifications

• High School Diploma
• 3+ years of experience in HMI development
• Experience with ABB and Fanuc robots
• Experience with welding, riveting, flow drill screws, lasers or similar joining processes
• Knowledge of Ethernet/IP, ControlNet, Devicenet protocols
• PC setup - software and hardware configuration
• Familiarity with die casting processes and machinery is a plus
• Bachelor’s degree in electrical or mechanical engineering is preferred

Responsibilities

• Design and implement control systems for die casting machines and automation equipment.
• Program, configure, and troubleshoot PLCs (Allen-Bradley, Siemens).
• Develop and maintain HMIs for operators to monitor and control processes.
• Integrate control systems with material handling, robotics, and production line equipment.
• Analyze performance to optimize cycle time, reduce waste, improve quality, and boost productivity.
• Provide on-site troubleshooting and technical support for PLCs, HMIs, sensors, and actuators.
• Ensure safety standards (ISO, OSHA, NFPA) compliance and safety protocols.

Skills

HMI Development

ABB robots

Fanuc robots

Welding

Riveting

Flow drill screws

Lasers

Ethernet/IP

ControlNet

DeviceNet

PC setup

Die casting knowledge

Education

Bachelor's degree in electrical or mechanical engineering

Tools

AutoCAD

Autodesk Inventor

Job description

Job Location:

Shelbyville, KY. Must be local or willing to relocate. Relocation assistance available to eligible candidates.

SUMMARY

The Controls Engineer for Die Casting is responsible for designing, programming, and maintaining the control systems that manage die casting operations. This includes overseeing automation systems, troubleshooting issues, and optimizing the performance of machines used in the die casting process, including die casting machines, furnaces, robotic arms, conveyors, and cooling systems.

DUTIES AND RESPONSIBILITIES

• Design and implement control systems for die casting machines and associated automation equipment, ensuring smooth operation and integration with other systems.
• Program, configure, and troubleshoot PLCs (e.g., Allen-Bradley, Siemens) that control key functions in the die casting process, such as metal injection, mold ejection, cooling, and part handling
• Develop and maintain Human-Machine Interfaces (HMIs) for operators, providing a user-friendly interface to monitor and control the die casting process.
• Integrate the die casting control systems with other plant equipment and systems such as material handling, robot arms, and production line machinery.
• Continuously analyze the performance of die casting systems and recommend improvements to optimize cycle time, reduce waste, enhance quality, and increase productivity.
• Continuously analyze the performance of die casting systems and recommend improvements to optimize cycle time, reduce waste, enhance quality, and increase productivity.
• Provide on-site troubleshooting and technical support for issues related to control systems, including PLCs, HMIs, sensors, and actuators.
• Ensure that control systems comply with safety standards (e.g., ISO, OSHA, NFPA) and implement safety protocols to protect personnel and equipment.
• Collect and analyze process data to identify trends, root causes of problems, and opportunities for improvement. Provide detailed reports and recommendations to management.
• Work closely with mechanical, electrical, and process engineers to optimize die casting operations and ensure seamless integration of control systems with machinery.
• Train operators and maintenance staff on the operation and troubleshooting of control systems. Provide ongoing technical support for new system upgrades or changes.
• Maintain detailed records of control system designs, configurations, and changes. Create standard operating procedures (SOPs) for system operations and troubleshooting.

QUALIFICATIONS:

MINIMUM REQUIRED:

• High School Diploma
• 3+ years of experience in the following:
• HMI Development
• ABB and Fanuc robots
• Welding, Riveting, Flow drill screws, Lasers, and other joining process controllers
• Communications protocols: Ethernet/IP, ControlNet, Devicenet
• PC setup - software and hardware configuration
• Familiarity with die casting processes and machinery is a significant advantage.

PREFERRED:

• Bachelor’s degree in electrical or mechanical engineering with prior controls and electrical work background
• Experience designing, building, and wiring industrial controls cabinets
• Stamping press line automation experience preferred - FOL de-stacking, washer/oiler, centering systems, inter-press, and conveyor systems
• Software: AutoCAD, Autodesk Inventor, and experience working with 30 CAD models
• Experience with Visual Basic, Visual C++, or other programming languages

WORK CONDITIONS:

• Exposure to loud noises
• Stand, walk, sit, use hands, reach & grasp, climb, stoop, kneel, crouch, climb, talk & vision, lift up to 30lbs