Controls Process Engineer, Coating and Bonding

CrossFire Group; Warsaw (IN); On-site; USD 100,000 - 130,000; Full time

Job summary

CrossFire Group is seeking a seasoned Controls Process Engineer for Coating & Bonding to design, implement, launch, and improve automotive production systems. You will ensure controls architecture and processes meet specifications and safety standards while supporting manufacturing and project teams.

The role focuses on developing electrical/controls documentation, collaborating with suppliers, supporting MES integration, driving OEE improvements, and mentoring maintenance and operations staff

Qualifications

• Bachelor's degree in Automation & Controls Engineering, Electrical Engineering, Electronics Engineering, Information Technology, or related field.
• 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 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.

Responsibilities

• 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).

Skills

PLC programming

Troubleshooting

Automation concepts

OEE knowledge

Education

Bachelor's degree in Automation & Controls Engineering / Electrical / Electronics / Information Technology

Tools

Siemens TIA Portal

WinCC

OPC UA

MES integration

Fanuc robotics

Job description

Controls Process Engineer, Coating & 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.

Key Responsibilities

• 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).

Required Qualifications

• 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.

Preferred Qualifications

• 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.

Key Competencies

• 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

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