Job Description

Assists with the development of all aspects of control systems, equipment, and machinery.

Key Responsibilities:

Assists with the development and design of control systems; assists with the development and implementation of bench tests; alters software and equipment to ensure that sensors and actuators are functioning according to specifications; supports and debugs basic problems and change requests. Assists with the preparation of cost estimates; compiles required cost and equipment information, and drafts appropriation requests. Investigates problems and requirements of projects, and develops plans for solutions in line with economic, personnel, and environmental considerations for review by more experienced Controls Engineers or Controls Engineering Manager. May be responsible for the installation and technical support of Programmable Logic Controller (PLC) based hardware and software. Competencies:

Collaborates - Building partnerships and working collaboratively with others to meet shared objectives.

Communicates effectively - Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences.

Health and Safety Fundamentals - Champions and models proactive health and safety behaviors by identifying, reporting and participating in actions to improve health and safety in order to build an interdependent culture and contribute to an injury-free workplace.

Controls Engineering Knowledge - Applies the application of controls hardware and software by specifying, reviewing, and approving company-owned and/or supplier designs for new or upgrades to existing equipment to interface with all levels of manufacturing systems.

Controls Networking - Implements new and improved technologies and methods capable of transferring information from multiple inputs either within a local production process or into databases to link machines together or to analyze the process for overall operation enhancements.

Controls Safety - Recognizes controls related hazards in a manufacturing environment (Electrical, Hydraulic, Pneumatic) to incorporate safe practices and procedures as part of the daily work plan to reduce injuries and create a safe machine environment.

Controls System Security - Develops and implements Controls System Security by specifying, reviewing, and approving company-owned and/or supplier designs for new equipment or upgrades to existing equipment to ensure our manufacturing controls and systems are secure.

Electrical System Troubleshooting - Analyzes an electrical control system to resolve and repair electrical issues to return the system to proper operating conditions.

Factory Automation and Control Systems - Implements changes to further automate manufacturing processes using available technology, programming techniques, and identifying needed material and resources for project completion to provide the optimum automation for the manufacturing environment.

Sensor Technology and Measurement - Selects and applies the sensor technology, performing measurements in the acquired data that leads to the correct analysis and conclusion to help differentiate products that meet quality standards from non-conforming products.

Values differences - Recognizing the value that different perspectives and cultures bring to an organization.

Manufacturing Knowledge - Demonstrates the knowledge of manufacturing by correctly implementing changes in current processes, equipment, and applications to meet the function's needs and contribute towards continuous improvement.

Machine Programming - Creates factory floor machine programs by designing and implementing solutions to improve usage of machine and overall operation.

Education, Licenses, Certifications:

College, university, or degree in STEM (Science, Technology, Engineering, Math) or related field, or equivalent experience required.
This position may require licensing for compliance with export controls or sanctions regulations.

Experience:

Basic level of relevant experience required.

The Controls Engineer is responsible for supporting and improving manufacturing automation systems to achieve safety, quality, delivery, and cost objectives. This role provides electrical maintenance and automation support through PLC programming, robotics integration, control system development, troubleshooting, commissioning, and process optimization. Working closely with cross-functional teams, the Controls Engineer ensures reliable and efficient operation of production equipment, drives continuous improvement initiatives, and maintains compliance with safety, quality, and operational standards. The position requires the ability to work independently with limited supervision and flexibility to support shift-based manufacturing operations as needed.

Key Responsibilities

Safety, Quality & Compliance

• Ensure compliance with Cummins Health, Safety, Environmental (HSE), quality, and manufacturing standards.
• Enforce Lockout/Tagout (LOTO), Permit to Work systems, machine safety requirements, PPE compliance, and safety PLC standards.
• Conduct risk assessments, safety audits, and machine safety validations, including interlocks, emergency circuits, and guarding systems.
• Promote 5S, housekeeping, and continuous improvement practices to maintain a safe and efficient work environment.

Controls Engineering & Automation

• Develop, modify, troubleshoot, and optimize PLC programs, robot logic, HMI/SCADA applications, and automation control systems.
• Design and implement end-to-end automation solutions, including control philosophy, sequence logic, and safety architecture for manufacturing equipment and production lines.
• Program, configure, and support Siemens S7-1500 PLCs, ABB, FANUC, and Yaskawa robotic systems.
• Integrate robots, vision systems, conveyors, manipulators, servo drives, VFDs, safety PLCs, sensors, and other automation devices.
• Configure and maintain industrial communication networks such as Profinet, Ethernet/IP, Modbus.
• Develop standardized control architectures, reusable software modules, and automation best practices.
• Support Industry 4.0, machine connectivity, predictive maintenance, cybersecurity, and digital manufacturing initiatives.

Equipment Reliability & Manufacturing Support

• Lead installation, commissioning, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and production ramp-up activities.
• Troubleshoot complex automation, electrical, robotics, hydraulic, and pneumatic system issues to minimize downtime and improve equipment reliability.
• Drive preventive, predictive, and corrective maintenance programs using CMMS systems such as MAXIMO.
• Conduct Root Cause Analysis using structured methodologies (5 Why, Fishbone, FTA) and implement sustainable corrective actions.
• Monitor and improve equipment performance through OEE, MTBF, MTTR, cycle time, throughput, and reliability improvements.
• Coordinate maintenance and automation activities with production, quality, suppliers, and OEMs to support manufacturing objectives.

Continuous Improvement & Project Management

• Identify and implement process optimization opportunities to improve productivity, quality, safety, and cost performance.
• Support capital projects through technical evaluation, cost estimation, appropriation requests, equipment specifications, and project execution.
• Lead cost reduction initiatives focused on maintenance efficiency, energy conservation, spare optimization, and waste elimination.
• Prepare technical documentation, engineering reports, control narratives, project plans, and operating procedures.

Team Leadership & Technical Development

• Provide technical leadership and hands-on support to technicians, trainees, and junior engineers across shifts.
• Coach, mentor, and develop team members to strengthen controls, automation, and troubleshooting capabilities.
• Lead shift meetings and maintenance reviews to communicate safety requirements, production priorities, and operational targets.
• Manage contractors and service providers to ensure work is completed safely, efficiently, and in compliance with company standards.

Planning & Resource Management

• Plan and manage critical spare parts inventory to support automation system reliability and business continuity.
• Track maintenance and automation performance metrics, ensuring achievement of uptime, reliability, quality, and cost objectives.
• Support resource planning and budgeting activities while driving continuous improvement in maintenance and automation performance
• Work in rotational shifts as per operational and business requirements.

Qualifications and Competencies

Qualifications

• Bachelor’s degree in engineering, Automation, Electrical Engineering, Electronics Engineering, Mechatronics, STEM-related field, or equivalent experience.
• Intermediate level of relevant automation, controls engineering, or manufacturing experience. Equivalent engineering qualification with relevant Industry experience may also be considered.

Preferred Skills

• Experience in automotive, manufacturing, industrial automation, or robotics environments.
• Siemens S7-1500 PLC programming and troubleshooting.
• Robotics programming, teaching, commissioning, and troubleshooting (ABB, FANUC, Yaskawa).
• HMI and SCADA development and support.
• Automation and control system integration.
• Industrial networking technologies including Profinet, Ethernet/IP, Modbus, and OPC UA.
• Servo drives, VFDs, sensors, actuators, motion control, and control system hardware.
• PLC programming languages including Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
• Advanced troubleshooting of electrical and automation systems.
• Machine safety systems, Safety PLCs, LOTO, and industrial safety standards.
• Controls system cybersecurity and network architecture.
• Manufacturing process automation and continuous improvement methodologies.
• Certifications or specialized training in PLC programming, robotics, SCADA, or industrial automation.

Qualifications

Skills & Experience

• 3-5 years of hands-on Mechatronics maintenance experience, specifically with PLC’s and Assembly line machines.
• Siemens S7-1500 PLC programming and troubleshooting.
• Robotics programming, teaching, commissioning, and troubleshooting (ABB, FANUC, Yaskawa).
• HMI and SCADA development and support.
• Automation and control system integration.
• Industrial networking technologies including Profinet, Ethernet/IP, Modbus, and OPC UA.
• Servo drives, VFDs, sensors, actuators, motion control, and control system hardware.
• PLC programming languages including Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
• Advanced troubleshooting of electrical and automation systems.
• Machine safety systems, Safety PLCs, LOTO, and industrial safety standards.
• Controls system cybersecurity and network architecture.
• Manufacturing process automation and continuous improvement methodologies.

Cummins is an equal opportunity employer. Our policy is to provide equal employment opportunities to all qualified persons without regard to race, sex, color, disability, national origin, age, religion, union affiliation, sexual orientation, veteran status, citizenship, gender identity, or other status protected by law.