Senior Automation Controls Engineer

Dexian; Illinois; On-site; USD 90,000 - 130,000; Full time

Job summary

Dexian is seeking a Senior Automation Controls Engineer in Toledo, OH for a 12-month contract with possible extensions. You will be the production line controls expert, troubleshooting issues during production and implementing changes, upgrades or configurations for future production needs.

This role is onsite in the Bodyshop and requires shift rotation between 1st and 2nd shifts, 72 hours per week. Key duties include participating in controls buy-offs at vendor sites and at the Client's factory

Qualifications

• BS/MS in Electrical Engineering or equivalent is required.
• 5–7 years of controls engineering experience or equivalent.
• Expertise with common controls hardware in high-volume manufacturing.
• Hands-on experience integrating and commissioning high-volume manufacturing equipment.
• In-depth knowledge of Safety standards (ANSI/RIA15.06, OSHA).
• Experience in safety design reviews and validating equipment safeties during buy-off.
• In-depth knowledge of Electrical Standards (NFPA79, NEC, UL508A).
• Experience developing electrical schematics using EPLAN/AutoCAD Electrical or similar.
• Advanced proficiency programming IEC 61131-3 languages.
• Experience writing standard and safety PLC projects from scratch.
• Experience creating HMI projects using FactoryTalk View, Ignition, or similar.
• Experience programming and troubleshooting 6-axis robots (Fanuc, ABB, Kawasaki, Nachi) is preferred.
• Knowledge of fieldbus networks like Ethernet/IP, EtherCAT or Profinet.

Responsibilities

• Participate in controls equipment buy-offs at vendor sites and at Client's factory for FAT, SAT, and safety.
• Develop controls standards and specifications from lessons learned to improve future projects.
• Reduce cycle time, downtime, and improve quality on production lines.
• Maintain, modify, and version control equipment programs, configs, and documentation (hardware, electrical, safety, pneumatic, network, PLC, HMI, MES).
• Add or remove network devices and update switch configurations as needed.
• Troubleshoot and enhance PLCs using Ladder Logic and Structured Text with maintainable code.
• Enhance HMIs to be user-friendly and suitable for operation and troubleshooting.
• Implement MES logic in PLCs and HMIs for production and performance management.
• Ensure ANSI/RIA15.06/OSHA compliant safety systems for safeguarding robots and conveyors.
• Train Production and Maintenance teams in proper use of equipment and troubleshooting via HMI.

Skills

Controls engineering

Electrical engineering background

IEC 61131-3 programming

PLC/HMI programming

Safety standards knowledge

Troubleshooting

Shift rotation capability

Education

BS/MS Electrical Engineering

Tools

EPLAN

AutoCAD Electrical

FactoryTalk View

Ignition

HMI

PLC

Job description

Title: Senior Automation Controls Engineer

Location: Toledo OH (Onsite)

Job Type: 12-Month Contract with possible extensions

Shifts: Must be able to support 1st and 2nd shift on rotation.

• 1st Shift - 6am-6pm
• 2nd Shift - 6pm-6am

Rotation: Every 2-4 weeks

Hours per week: 72 hours

About the Role:

The Sr. Automation Controls Engineer for Equipment Engineering are the production line experts for controls. The team troubleshoots any technical issues during production, sometimes working with engineers on any changes, upgrades or configurations that are needed for future production changes. The area where you will work is Bodyshop. This role is located at Toledo OH, facility and reports directly to the Manager, Automation Controls Engineering.

Responsibilities:

• Participate in various controls equipment buy-offs at vendor sites and at Client's factory in Normal, IL for FAT, SAT, and safety.
• Participate in development of controls standards and specifications by feeding back lessons-learned and gaps from each project to ensure that future projects will run smoother.
• Continuously improve the production lines by reducing cycle time, reducing downtime, production support, and improving quality.
• Maintain, modify, and properly version control equipment programs, configuration files, and documentation as changes are implemented. This includes but is not limited to hardware, electrical, safety, pneumatic, network, PLC, HMI, Robot, SCADA, and MES.
• Add or remove network devices from the equipment as needed, updating network switch configurations as needed.
• Troubleshoot, improve, and add features to PLCs using Ladder Logic and/or Structured Text with an emphasis on code that is organized, structured, documented, maintainable and reusable.
• Troubleshoot, improve, and add features to HMIs to make them more user-friendly, intuitive and suitable for operating and troubleshooting equipment.
• Implement and make modifications to MES logic for production and performance management in the PLCs and HMIs.
• Ensure proper implementation of and modifications to (ANSI/RIA15.06/OSHA compliant) control reliable safety systems for safeguarding robots, gantries, conveyors, and other high volume manufacturing equipment.
• Client Internal.
• Train Production and Maintenance teams in proper use of the equipment and troubleshooting from the HMI.

Qualifications:

• 5-7 years of Controls Engineering experience or equivalent work experience.
• BS/MS Electrical Engineering or equivalent work experience.
• Expertise with common controls hardware components used in high-volume manufacturing.
• Hands-on experience integrating and commissioning high volume manufacturing equipment.
• In-depth knowledge of Safety standards (ANSI/RIA15.06, OSHA).
• Experience participating in safety design reviews and validating equipment safeties during buy-off.
• In-depth knowledge of Electrical Standards (NFPA79, National Electric Code, UL508A).
• Experience developing electrical schematics using EPLAN, AutoCAD Electrical, or similar.
• Advanced proficiency programming industrial equipment using various IEC 61131-3 languages.
• Experience writing standard and safety PLC projects from scratch for high-volume manufacturing equipment using PLCs.
• Experience creating HMI projects from scratch for high-volume manufacturing equipment using FactoryTalk View, Ignition, HMI, or similar.
• Experience programming and troubleshooting industrial 6-axis robots such as Fanuc, ABB, Kawasaki, Nachi, etc. is preferred.
• Experience troubleshooting common fieldbus networks such as Ethernet/IP, EtherCAT, or Profinet.
• Knowledge of communications between machine PLCs and database systems.
• Ability to rotate shifts

Dexian is an Equal Opportunity Employer that recruits and hires qualified candidates without regard to race, religion, sex, sexual orientation, gender identity, age, national origin, ancestry, citizenship, disability, or veteran status.