Controls Engineer, Ford Energy

Ford; Glendale (KY); On-site; USD 65,000 - 166,000; Full time

Benefits offered by this job

Vehicle discount program

Tuition assistance

Paid time off

Job summary

Ford Energy, a Ford Motor Company subsidiary, is launching a state-of-the-art BESS manufacturing facility in Glendale, Kentucky. The Controls Engineer will design, implement, and optimize automated systems for grid-scale energy storage production, collaborating with cross-functional teams to ensure high reliability and performance.

Ideal candidates will have a engineering degree, hands-on experience with PLCs and robotics, and a strong problem-solving mindset.

Qualifications

• Bachelor's degree in engineering is required.
• Maintenance experience or internships in manufacturing.
• Flexibility to work across shifts and travel domestically.
• Ability to troubleshoot to root cause and across cross-functional teams.

Responsibilities

• Program, modify, and troubleshoot machinery with PLCs and HMIs.
• Coordinate servo, frequency, and upper-level computer interfaces.
• Support and integrate Fanuc robots with automation systems.
• Lead fault analysis to prevent recurrence and fix faults.
• Develop preventive maintenance plans and mentor technicians.
• Support design changes and update control models and backups.

Skills

Siemens SP700 PLC programming

Omron PLC programming

HMI programming

Robot programming (Fanuc)

Automation troubleshooting

Preventive maintenance planning

Electrical fault analysis

System integration

Model/code updates

Leadership/mentoring

Education

Bachelor's degree in engineering

Master's degree in engineering

Tools

RSLOGIX

AutoCAD

Siemens/Omron automation hardware

Job description

Ford Energy is a newly formed, wholly-owned subsidiary of Ford Motor Company dedicated to accelerating U.S. energy independence. Leveraging Ford’s century of manufacturing excellence and world-class battery energy storage systems (BESS) technology, Ford Energy designs, manufactures, and services grid-scale and commercial DC battery energy storage systems (BESS). Ford Energy is uniquely positioned to capture the growing demand for reliable, US-built energy storage systems. We are not just building batteries; we are building the infrastructure for the next generation of the American grid.

Why Ford Energy? At Ford Energy, you have the backing of an industrial manufacturing powerhouse with the agility of a dedicated energy startup offering industry leading technology. We offer a competitive compensation package including performance-based bonuses, Ford vehicle discounts, and the opportunity to shape the energy strategy of one of the world's most iconic brands.

In this position... As a Controls Engineer, you will be on the ground floor launching a state-of-the-art BESS manufacturing facility in Glendale, Kentucky. As a key member of our start-up team, you will have a once-in-a-lifetime opportunity to help build and program the automated systems that bring next-generation energy storage products to the grid. In this critical role, you will:

Optimize with Precision: Provide technical expertise to optimize highly automated manufacturing equipment and processes through visual systems, automation, and advanced levels of process control.

Innovate: Apply an entrepreneurial mindset to deliver data-driven controls solutions for battery cell and BESS module/container manufacturing lines.

Drive Excellence: Be the go-to technical expert for automation reliability, ensuring the facility operates with the precision required to deliver world-class energy products.

What you'll do...

Operational Excellence – Controls & Automation

• Program, modify, and troubleshoot machinery utilizing Siemens (SP700), Omron, or other PLC programming software and HMI screens.
• Manage the interaction between servo systems, frequency conversion systems, and upper-level computers; configure parameters appropriately for varying production loads.
• Support and troubleshoot robotic systems (such as Fanuc), including robot programming and integration with other automation systems.
• Lead fault analysis and root cause identification for complex automation issues to prevent recurrence; identify and rectify electrical component faults.
• Establish preventive maintenance plans for equipment and electrical/controls aspects, and mentor/train technicians to enhance the team's overall competence.
• Support feasibility on product design changes and lead modifications, model code updates, and program backups for automation.

Leadership – Culture

• Embrace the Gemba philosophy: Regularly engage on the floor to monitor automation health, listen to technicians, and solve problems where the work happens.
• Remove Barriers: Use Andon data to prioritize efforts to achieve 100% flow; lead Six Sigma project teams focused on efficiency, quality, and reliability.
• Collaborate across functions: Act as a liaison with IT on IT/Controls interface issues and work with Manufacturing Engineering to ensure efficient installation and validation of new equipment.
• Ability to demonstrate leadership behaviors combined with outstanding interpersonal and communication skills.
• Ensure adherence to the Ford Production System (FPS) and Safety Operating System practices to achieve zero injuries.

Strategic – Reliability

• Provide input on new equipment design and controls architecture as the site builds out battery cell and BESS assembly capacity.
• Support new model and equipment launches as required.
• Report out on key metrics around automation performance and equipment reliability.

Capabilities for Success

• Resilient Problem Solver: Able to troubleshoot complex automation and controls issues to identify root cause quickly.
• Self-Starter: Takes ownership of projects and drives them to completion with limited supervision.
• Strong Communicator: Bridges the gap between shop floor technicians and corporate engineering teams.
• Agile Mindset: Comfortable working across shifts and navigating the ambiguity of a startup manufacturing environment.

You'll have...

• Bachelor's degree in engineering
• Maintenance experience, including internships, with the ability to optimize equipment programs and troubleshoot to root cause.
• Flexibility to support business needs by working across various shifts
• Domestic and international travel may be required

Even better, you may have...

• Master's degree in engineering
• 5+ years of relevant Controls Engineering experience
• Familiarity with Data Collection, AI/ML, IIOT, and Digital Twins
• Prior experience with Fanuc, ABB, or Universal robots
• Experience with Lean Manufacturing, Six Sigma, and FMEAs
• Proficiency in AutoCAD, C, and RSLOGIX
• Skills: Computer efficiency; excellent communicator able to train hourly and salary team members

As an established global company, we offer the benefit of choice. You can choose what your Ford future will look like: will your story span the globe, or keep you close to home? Will your career be a deep dive into what you love, or a series of new teams and new skills? Will you be a leader, a changemaker, a technical expert, a culture builder…or all of the above? No matter what you choose, we offer a work life that works for you, including:

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

This position is a range of salary grade 5-8 and ranges from $65,100-$166,200.
Final determination of salary grade will be based on candidate's skills and experience, and base salary will be set within the applicable range according to job scope, responsibility and competitive market value.

Visa sponsorship is not available for this position.
Candidates for positions with Ford Motor Company must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.
We are an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, religion, color, age, sex, national origin, sexual orientation, gender identity, disability status or protected veteran status. In the United States, if you need a reasonable accommodation for the online application process due to a disability, please call 1-888-336-0660.

Company: As Ford establishes a wholly owned subsidiary focused on Battery Energy Storage Systems, this role will initially be employed by Ford and is expected to transition to the subsidiary within one year.