Controls Process Engineer, Coating and Bonding

CrossFire Group; Warsaw (IN); On-site; USD 109,000 - 163,000; Full time

Job summary

CrossFire Group in the United States is seeking a seasoned Controls Process Engineer, Coating & Bonding, to design, implement, launch, and improve automotive production systems. You will ensure equipment, controls architecture, and processes meet specifications and industry best practices.

After launch, you will troubleshoot automation issues, drive continuous improvement, and lead projects with suppliers and engineers while maintaining safety and environmental standards.

Qualifications

• Bachelor's degree in Automation & Controls Engineering or related technical discipline.
• Minimum 8 years in automotive manufacturing.
• Experience with controls design, development, commissioning, and troubleshooting.
• Proficiency with Siemens TIA Portal, WinCC, and OPC UA.
• Experience integrating MES, robotics, vision systems, sealing systems, and other automation technologies.
• Strong PLC programming experience, including Allen-Bradley control systems.
• Experience with automated dispensing and process control systems.
• Working knowledge of industrial robotics, including Fanuc.
• Knowledge of NFPA electrical standards and safety requirements.
• Experience supporting BIW bonding and sealing processes.
• Strong project management and problem-solving skills.

Responsibilities

• Develop and maintain electrical and controls documentation, including specifications and acceptance criteria.
• Define and support system requirements for SCADA, ANDON, torque tools, AGVs, robotics integration, and automation technologies.
• Collaborate with suppliers, integrators, and line builders during project planning, design, installation, and commissioning.
• Ensure controls and automation standards are applied across manufacturing operations.
• Support operations through improvements in reliability, facility controls, data collection, and backups.
• Assist with MES integration and third-party automation equipment.
• Provide technical guidance and knowledge transfer to maintenance, engineering, and operations teams.
• Support coating, sealing, and bonding processes through system optimization and training.
• Lead projects with contractors to meet schedule and budget.
• Maintain compliance with quality, safety, IP, and environmental requirements.
• Lead continuous improvement initiatives focused on productivity and OEE.

Education

Bachelor's degree in Automation & Controls Engineering

Tools

Siemens TIA Portal

WinCC

OPC UA

Allen-Bradley PLC

Fanuc robotics

MES integration

Job description

Job Description

Job Description Controls Process Engineer, Coating and Bonding

Position Summary The Controls Process Engineer, Coating & Bonding, will work closely with manufacturing and project teams to support the design, implementation, launch, and continuous improvement of automotive production systems. This role is responsible for ensuring equipment, controls architecture, and manufacturing processes are delivered according to established specifications and industry best practices.

Following facility launch, the Controls Process Engineer will support production operations by troubleshooting and resolving controls, automation, and process-related issues to minimize downtime and maximize equipment efficiency. The role also plays a key part in driving continuous improvement initiatives while maintaining compliance with safety, environmental, and quality standards.

• Develop and maintain electrical and controls documentation, including specifications and technical acceptance criteria.
• Define and support system requirements related to SCADA, ANDON systems, torque tools, AGVs, robotics integration, safety controls, and related automation technologies.
• Collaborate with equipment suppliers, integrators, and line builders during project planning, design, installation, and commissioning phases.
• Ensure controls and automation standards are consistently applied across manufacturing operations.
• Support manufacturing operations through improvements in equipment reliability, facility controls, software applications, data collection, and backup processes.
• Assist with the implementation and integration of Manufacturing Execution Systems (MES) and third-party automation equipment.
• Provide technical guidance and knowledge transfer to maintenance, engineering, and operations teams.
• Support coating, sealing, and bonding processes through system optimization and training initiatives.
• Partner with contractors, suppliers, and integrators to deliver projects on schedule and within budget.
• Maintain compliance with company standards related to quality, safety, intellectual property, and environmental requirements.
• Lead continuous improvement initiatives focused on productivity, equipment performance, and Overall Equipment Effectiveness (OEE).

• Bachelor's degree in Automation & Controls Engineering, Electrical Engineering, Electronics Engineering, Information Technology, or a related technical discipline.
• Minimum of 8 years of manufacturing experience within the automotive industry.
• Experience with controls system design, development, commissioning, and troubleshooting.
• Proficiency with Siemens automation platforms, including TIA Portal, WinCC, and OPC UA.
• Experience integrating MES platforms, robotics, vision systems, sealing systems, and other industrial automation technologies.
• Strong PLC programming experience, including Allen-Bradley control systems.
• Experience with automated dispensing and process control systems.
• Working knowledge of industrial robotics, including Fanuc and similar robotic platforms.
• Understanding of process engineering principles and OEE performance metrics.
• Knowledge of NFPA electrical standards and industrial safety requirements.
• Experience supporting Body-in-White (BIW) bonding and sealing processes.
• Strong project management, organizational, and problem-solving skills.

• Experience supporting brownfield manufacturing facility launches and expansions.
• Knowledge of coating, sealing, adhesive, and bonding applications within automotive manufacturing.
• Experience leading automation-focused continuous improvement initiatives.
• Ability to effectively collaborate with cross-functional teams, suppliers, and external partners.

• Continuous improvement mindset
• Strong analytical and troubleshooting abilities
• Effective communication and collaboration skills
• Results-driven approach with strong execution focus
• Leadership through influence and technical expertise
• Commitment to safety, quality, and operational excellence

Compensation Base Salary Range: $108,877 - $163,316 annually Actual compensation will be based on several factors including relevant experience, technical expertise, education, certifications, location, and overall qualifications.