Controls Engineer

100249 Saia-Burgess LLC; Vandalia (MO); On-site; USD 65,000 - 90,000; Full time

Job summary

Johnson Electric seeks a Process Engineering Technician to drive smooth transitions from prototype to production, optimize PLC-based automation, and support AI‑enabled improvements across manufacturing lines.

You will qualify products using IQ/OQ/PQ/FQ, validate tests, and train operators while collaborating with cross‑functional teams to reduce waste and improve reliability in a diverse production environment.

Qualifications

• Minimum 3 years’ experience in JMT assembly or similar manufacturing environments.
• Hands-on experience with PLC programming, troubleshooting, and logic modification (Allen‑Bradley, Siemens, or equivalent preferred).
• Experience with industrial vision systems for inspection and verification.
• Knowledge of data and signal processing, including interpreting machine outputs for diagnostics and process improvement.
• Familiarity with automation systems, robotics interfaces, sensors, and machine control integration.
• Understanding of mechanical controls, pneumatics, actuators, and electromechanical systems.
• Ability to use measurement equipment during qualification runs.
• Strong attention to detail; ensures new processes are robust and well‑documented.
• Proactive attitude toward identifying potential waste, safety risks, or quality concerns.
• Willingness to adopt and support AI‑enabled tools for analysis and improvement.

Responsibilities

• Run IQ, OQ, PQ, and FQ protocols to qualify products.
• Conduct test method validations to ensure new testers meet performance requirements.
• Integrate, troubleshoot, and optimize PLC‑based automation systems and electrical controls on production equipment.
• Configure and support industrial vision systems used for inspection, error proofing, and quality verification.
• Analyze equipment signals, machine data, and sensor outputs; support AI‑assisted predictive maintenance and equipment optimization.
• Facilitate prototype builds and document production readiness issues.
• Execute and document pilot builds to ensure manufacturing validation.
• Create work instructions and support smooth transitions to production.
• Verify and optimize cycle times to ensure compliance with engineering estimates.
• Train operators on new processes, controls, and automation systems.
• Collaborate with cross‑functional teams to resolve issues and enhance manufacturing processes.
• Support continuous improvement initiatives aimed at reducing waste, improving automation reliability, and simplifying processes.

Skills

PLC programming

Troubleshooting

Vision systems

Data interpretation

Automation systems

Electromechanical systems

Measurement equipment

Job description

Process Engineering Technician – Johnson Electric

Location: Vandalia, OH (onsite) | Travel: 5–10% (domestic and international)

As our next Process Engineering Technician, you’ll play a key role in introducing new products to the production line efficiently and effectively. Your expertise will ensure smooth transitions from prototype to full-scale production while maintaining quality and reducing waste.

Why You’ll Love Working Here

• Strong Leadership: Work under experienced and visionary leaders who guide the company towards success.
• Innovation Hubs: Access to state-of-the-art facilities and innovation hubs that foster creativity and development.
• Employee Empowerment: A culture that empowers employees to take initiative and make impactful decisions.
• Diverse Projects: Work on a variety of projects across different industries, gaining broad experience.
• Mentorship Opportunities: Access to mentorship programs that help you grow both personally and professionally.

What You’ll Be Doing

• Run IQ (Installation Qualifications), OQ (Operational Qualifications), PQ (Performance Qualifications), and FQ (Fixture Qualifications) protocols to qualify products.
• Conduct test method validations to ensure new testers meet performance requirements.
• Integrate, troubleshoot, and optimize PLC‑based automation systems and electrical controls on production equipment.
• Configure and support industrial vision systems used for inspection, error proofing, and quality verification.
• Analyze equipment signals, machine data, and sensor outputs; support AI‑assisted predictive maintenance and equipment optimization.
• Facilitate prototype builds and document production readiness issues.
• Execute and document pilot builds to ensure manufacturing validation.
• Create work instructions and support smooth transitions to production.
• Verify and optimize cycle times to ensure compliance with engineering estimates.
• Train operators on new processes, controls, and automation systems.
• Collaborate with cross‑functional teams to resolve issues and enhance manufacturing processes.
• Support continuous improvement initiatives aimed at reducing waste, improving automation reliability, and simplifying processes.

What We’re Looking For

• Minimum 3 years’ experience in JMT assembly or similar manufacturing environments.
• Hands‑on experience with PLC programming, troubleshooting, and logic modification (Allen‑Bradley, Siemens, or equivalent preferred).
• Experience with industrial vision systems for inspection and verification.
• Knowledge of data and signal processing, including interpreting machine outputs for diagnostics and process improvement.
• Familiarity with automation systems, robotics interfaces, sensors, and machine control integration.
• Understanding of mechanical controls, pneumatics, actuators, and electromechanical systems.
• Ability to use measurement equipment during qualification runs.
• Strong attention to detail; ensures new processes are robust and well‑documented.
• Proactive attitude toward identifying potential waste, safety risks, or quality concerns.
• Willingness to adopt and support AI‑enabled tools for analysis and improvement.

About Johnson Electric

Our purpose is to improve the quality of life of everyone we touch through our innovative motion systems. We are a truly global team bound together by our shared values. Our culture is built on the diversity, knowledge, skills, creativity, and talents that each employee brings to the company. Our people are our company’s most valuable asset. We are committed to providing an inclusive, diverse and equitable workplace where employees of different backgrounds feel valued and respected, regardless of their age, gender, race, ethnicity or religious background. We are committed to inspiring our employees to grow, act with ownership and find fulfilment and meaning in the work they do.

Johnson Electric Group

The Johnson Electric Group is a global leader in electric motors, actuators, motion subsystems and related electro‑mechanical components. It serves a broad range of industries including Automotive, Smart Metering, Medical Devices, Business Equipment, Home Automation, Ventilation, White Goods, Power Tools, Lawn & Garden Equipment, Warehouse Automation, Liquid Cooling and Robotic joints. The Group is headquartered in Hong Kong and employs over 30,000 individuals in over 20 countries worldwide. Johnson Electric Holdings Limited is listed on The Stock Exchange of Hong Kong Limited (Stock Code: 179). For more information, visit johnsonelectric.com.