Senior Automation Engineer – PLC, Robotics & Controls Lead

IAC Group; Troy (MI); Hybrid; USD 110,000 - 140,000; Full time

Job summary

IAC Group in Troy, MI is seeking a Senior Controls Engineer to lead the design, development, and deployment of manufacturing control systems for automotive production. You will drive capital equipment projects from concept through launch, ensuring safety, quality, and productivity goals are met.

The role requires extensive PLC programming, robotics integration, and continuous improvement expertise, with opportunities to influence plant automation strategy, PFMEA participation, and

Qualifications

• Bachelor's degree in Electrical Engineering or related field.
• 7-10 years of controls engineering experience in manufacturing.
• Automotive Tier 1 supplier experience preferred.
• Experience with automation equipment, PFMEA participation, and continuous improvement.

Responsibilities

• Lead design, programming, commissioning, and validation of automated manufacturing equipment and control systems.
• Develop and modify PLC, HMI, servo, vision, and robotic control programs.
• Support launches ensuring controls meet timing, quality, and production requirements.
• Establish process parameters, equipment controls, and monitoring for quality and performance.
• Troubleshoot electrical, controls, automation, and process issues.
• Collaborate with manufacturing, quality, maintenance, product engineering, and suppliers.
• Lead root cause analysis and corrective actions for downtime and quality issues.
• Maintain controls documentation: schematics, network architecture, PLC/HMI backups, control plans, equipment standards.
• Participate in PFMEA and feasibility reviews.
• Support capital equipment sourcing, installation, validation, and startups.
• Train maintenance and production on operation, troubleshooting, and PM.
• Drive OEE, scrap, cycle-time, and cost-saving improvements.
• Ensure safety, environmental, and customer compliance.

Skills

PLC programming

Robotics integration

Process controls

Digital twins

Cybersecurity OT

Python scripting

Education

Bachelor's in Electrical Engineering

Tools

Allen-Bradley ControlLogix

Siemens S7/TIA Portal

Beckhoff TwinCAT

FANUC robotics

ABB robotics

EtherNet/IP

Ignition

PowerBI

Vidi Cognex Vision

Job description

IAC Group in Troy, MI is seeking a Senior Controls Engineer to lead the design, development, and deployment of manufacturing control systems for automotive production. You will drive capital equipment projects from concept through launch, ensuring safety, quality, and productivity goals are met.

The role requires extensive PLC programming, robotics integration, and continuous improvement expertise, with opportunities to influence plant automation strategy, PFMEA participation, and