Sr. Engineer, Electrical & Controls

Dormont Manufacturing Co; Rock Spring (KY); On-site; USD 110,000 - 150,000; Full time

Job summary

Astemo Rock Spring, Inc. in Rock Spring, GA, is seeking a Sr. Engineer, Electrical & Controls to lead automation projects and maintain control systems. You will design, program, and optimize PLC-based controls for automated manufacturing processes and support robotics and vision systems.

The role requires hands-on troubleshooting and the ability to manage projects from planning through commissioning, ensuring safety and compliance within production environments.

Qualifications

• 3–7+ years of experience in industrial automation or manufacturing electrical systems.
• Expertise with PLC programming, HMI and robotics support is preferred.
• Strong troubleshooting ability and hands-on electrical and controls skills.

Responsibilities

• Design, program, and maintain PLC-based control systems for automated processes.
• Support and optimize robotic systems and automated lines; integrate new equipment.
• Develop electrical schematics, PLC documentation, and control standards.

Skills

PLC programming

HMI systems

VFDs

Motion control

Industrial networks

Troubleshooting

Electrical schematics

Tools

Omron

Allen-Bradley

Siemens

Job description

Sr. Engineer, Electrical & Controls

Full-Time, Exempt, Engineering – Reports to: Department Head, Production Engineering. Based in Rock Spring, GA, at Astemo Rock Spring, Inc., a division of Astemo, Inc. with approximately 400 employees across Casting, Machining, and Press Assembly manufacturing departments.

Key Responsibilities

Automation & Controls Engineering

• Design, program, maintain, and improve PLC-based control systems used in automated manufacturing processes.
• Support and optimize robotic systems, automated assembly lines, material handling equipment, and process automation.
• Develop and maintain electrical schematics, PLC documentation, and control system standards.
• Integrate new equipment and automation technologies into existing production systems.
• Ensure compliance with plant automation standards and electrical codes.

Project Planning & Implementation

• Plan and lead electrical and automation projects including equipment upgrades, line modifications, and new production installations.
• Support equipment launches and production line startups.
• Work with vendors, integrators, and contractors to implement automation solutions.
• Establish and manage project timelines and budgets, providing timely updates to management on progress, risks, and overall performance.

Hands-On Troubleshooting & Production Support

• Provide hands‑on troubleshooting of electrical and automation issues affecting production.
• Diagnose and resolve problems involving:
  • PLC programs – Omron/Allen Bradley
  • Robotics systems – Yaskawa/Fanuc
  • HMI systems – Omron/Allen Bradley
  • Sensors and vision systems – Keyence, Omron, Turk
  • Servo drives and VFDs
  • Industrial networks
• Work with maintenance technicians to quickly restore equipment functionality during production downtime.
• Conduct root cause analysis of equipment failures and implement permanent corrective solutions.

Robotics & Advanced Automation

• Support robotic systems used in production and material handling operations.
• Troubleshoot robot communication with PLCs and automation equipment.
• Assist with robot programming, system adjustments, and integration with automated cells.
• Support safety systems including light curtains, safety PLCs, and interlock circuits.

Training & Technical Development

• Train maintenance technicians on electrical troubleshooting, PLC diagnostics, and automation systems.
• Develop training materials and technical documentation for automated equipment.
• Mentor technicians to improve their understanding of robotics, sensors, and control systems.
• Promote best practices in electrical safety and automation maintenance.

Safety & Environmental

• Promote and enforce a safety‑first culture, ensuring adherence to safety guidelines, procedures, and regulations.
• Implement and maintain stringent environmental practices aligned with relevant standards and regulations.

Quality

• Establish and maintain robust quality control processes for maintenance activities, ensuring adherence to quality standards and driving continuous improvement initiatives.
• Collaborate closely with Quality Assurance teams to identify opportunities for quality enhancement within the maintenance department.

Delivery

• Coordinate maintenance schedules effectively to minimize disruption to production activities and meet production goals.
• Work collaboratively with production teams to prioritize maintenance tasks based on criticality, ensuring on‑time completion and optimal equipment availability.
• Monitor performance metrics closely to optimize maintenance delivery, meet key performance indicators, and ensure timely completion of maintenance activities.

Productivity

• Proactively identify opportunities for productivity improvement within the maintenance department, engaging in continuous evaluation and optimization of processes.
• Implement measures to increase efficiency, reduce downtime, and optimize resource utilization in maintenance operations.
• Collaborate actively with cross‑functional teams to drive continuous improvement initiatives and achieve operational excellence.

Reporting

• Prepare regular comprehensive reports on maintenance activities, performance metrics, and improvement initiatives, providing valuable insights to the Site Head and senior management.
• Collaborate with team members to gather and analyze relevant data for reporting purposes, ensuring accuracy and reliability.

Preferred Skills

• Experience with PLC programming (Allen‑Bradley, Siemens, or similar).
• Experience with HMIs, VFDs, motion control, and industrial communication networks.
• Strong troubleshooting experience in manufacturing environments.

Technical Skills

• Industrial networks (EtherNet/IP, Modbus, Profinet, etc.)
• Electrical schematics and control panel design
• Robotics or automated manufacturing systems (preferred)
• Root cause analysis and reliability improvement

Minimum Experience

• 3–7+ years of experience in industrial automation or manufacturing electrical systems.

Core Competencies

• Strong planning and project management skills
• Hands‑on technical capability in electrical and controls systems
• Ability to execute projects from concept through commissioning
• Strong troubleshooting and problem‑solving skills
• Ability to train and develop technical personnel
• Excellent communication and collaboration skills

Key Metrics Responsibility

• Ensure equipment uptime and reliability through effective maintenance strategies.
• Maintain maintenance costs within budgetary constraints while maximizing value.
• Promote and enforce a safe work environment, minimizing safety incidents and ensuring compliance with regulations.
• Achieve on‑time delivery of maintenance activities to minimize disruption to production.
• Optimize maintenance productivity metrics, including preventive maintenance completion, work order turnaround time, and labor efficiency.

Physical Demands

• Work performed in a manufacturing environment with exposure to machinery, electrical equipment, and industrial processes.
• Ability to occasionally lift equipment and work around energized systems following safety procedures.
• Some off‑shift or weekend support may be required during projects or equipment downtime.

Equal Opportunity Employer Statement

Qualified applicants will receive consideration without regard to race, color, religion, sex, sexual orientation, gender identity, disability, protected veteran status, or national origin. Astemo is proud to be an equal opportunity employer.