Controls Engineer (1st Shift)

Magna International; Sterling Heights (MI); On-site; USD 70,000 - 90,000; Full time

Job summary

Magna International in Sterling Heights, Michigan is looking for a Controls Engineer to design and supervise electrical control systems for efficient plant operations. The ideal candidate should have a Bachelor’s degree or equivalent experience in Electrical Engineering, along with expertise in PLC programming, robotics, and HMI systems.

This role involves managing installations, troubleshooting equipment, and supporting Factory 4.0 initiatives. Magna values a diverse workforce and maintains a commitment to equal opportunity employment.

Qualifications

• Bachelor’s degree in Electrical Engineering or five years of experience required.
• Minimum five years’ experience in automotive manufacturing and PLC knowledge is essential.
• Knowledge of robotics and HMI programming preferred.

Responsibilities

• Design and develop plant electrical control systems.
• Install and support PLC-based hardware and software.
• Troubleshoot equipment and optimize performance.

Skills

PLC programming (Allen Bradley and Siemens)

Robotics (ABB and Fanuc)

HMI programming (RS Logic Suite, FTView)

Networking (Ethernet/IP, DH+, RIO)

Electrical schematics interpretation

Continuous improvement mindset

Microsoft Office suite

Education

Bachelor’s degree in Electrical Engineering

Electrical Engineering Technology certification

Five years of experience in automotive manufacturing

Tools

AS400

Job description

Job Responsibilities

The Controls Engineer is responsible for designing, developing, and supervising all aspects of the plant electrical control systems, equipment, and machinery. Responsibilities include the installation and technical support of PLC‑based hardware and software. The goal is to ensure the plant operates smoothly and efficiently while meeting quality and safety standards.

These duties cover the more significant responsibilities; additional duties may be assigned by the supervisor.

• Plan and execute new installations, upgrades, and continuous improvements with internal and external resources to support business goals.
• Read, modify, and troubleshoot PLC programs (Allen‑Bradley and Siemens preferred) using laptop computers.
• Work with Manufacturing and/or Quality to solve customer quality issues, analyze plant processes, and implement improvements based on extensive knowledge of electronics, engineering, and mechanics.
• Proactively develop improvement suggestions to enhance plant performance, equipment reliability, and uptime.
• Create programs to minimize and limit downtime.
• Ensure error‑proofing devices are programmed to be checked in real time and processes are stopped when malfunctions are detected.
• Ensure all sensors, processes, and relevant parameters are checked in real time to ensure process compliance and stop processes when malfunctions are detected.
• Write programs that provide sufficient information for operators to troubleshoot and maximize process capabilities while minimizing equipment wear and tear.
• Support implementation of Factory 4.0 initiatives.
• Create, verify, and maintain electrical control schematics and program documentation.
• Create and maintain backup programs for all programs and software in both locations to prevent loss.
• Design, develop, and improve new machine controls including CNC, robotics, transfer systems, electrical, hydraulic, pneumatic, and vision systems.
• Troubleshoot equipment and facility problems as they arise.
• Assist in defining statements of requirements, specifications, and standards for new and modified equipment.
• Assist in performing preventative and predictive maintenance activities as assigned.
• Repair equipment as needed.
• Develop a maintenance program for control systems and perform maintenance.
• Continuously improve the preventive maintenance program for control systems.
• Ensure compliance with company policies and procedures, including IATF 16949, Mafact, ISO14001 (EMS), and the Employee Handbook.
• Demonstrate ability to carry out projects from beginning to end in coordination with internal and external resources.
• Work independently or in teams on work assignments.
• Follow MIOSHA, Magna, and MPTSH safety regulations and policies, including wearing required PPE.
• Report unsafe conditions to Supervisor/Leader.

Education and Experience

Bachelor’s degree in Electrical Engineering or Electrical Engineering Technology certification, or five or more years of equivalent experience and education. Must have a minimum of five years’ experience in automotive manufacturing, strong knowledge of PLCs (Allen Bradley and Siemens), robotics (ABB and Fanuc) preferred, HMI programming (RS Logic Suite, FTView, Siemens Programming Suite), networking (Ethernet/IP, DH+, RIO, DeviceNet, ControlNet, RS232), electrical schematics interpretation, continuous improvement mindset, and ability to multitask. Working knowledge of OmniLinks and Wintress preferred.

Additional Skills

• Language: Ability to read and comprehend instructions in English and document forms as required.
• Mathematical: Ability to add, subtract, multiply and divide in all units of measure, compute rate, ratio, and percent.
• Computer: Knowledge of AS400 and proficiency in Microsoft Office suite (Word, Excel, PowerPoint).
• Mechanical: Comfortable with running and troubleshooting machinery; familiarity with electrical, hydraulic, and pneumatic systems.
• Reasoning: Apply common sense to carry out instructions furnished in written, oral, diagram, or schedule form.
• Problem Solving: Conduct structured problem solving individually or in teams; apply 5 Why methodology; research to identify root causes and find solutions; make decisions based on available information.
• Communication: Active listening, assertive communication, sufficient emotional intelligence.

Physical Demands

Frequent standing, walking, reaching with hands and arms, talking, and listening. Ability to maintain general good health in a fast‑paced, sometimes high‑stress environment. Occasionally required to climb, balance, stoop, kneel, crouch, crawl, and lift or move up to 50 pounds. Specific vision abilities required include close and distance vision and ability to adjust focus.

Work Environment

Work occurs in an office setting and on the plant floor. Noise levels are usually low to moderate in the office and moderate to loud on the production floor. Exposure to low levels of vibration occurs. Employees may be on the production floor where they encounter moving mechanical parts.

Equal Opportunity Employer

Magna believes that a diverse workforce is critical to our success. We are an equal‑opportunity employer and hire based on experience and qualifications, irrespective of color, ancestry, religion, gender, origin, sexual orientation, age, citizenship, marital status, disability, or gender identity. Magna respects the privacy of personal information and adheres to GDPR and local data privacy laws.