Controls Engineer

SUMMARY

• The Controls Engineer for Die Casting is responsible for designing, programming, and maintaining the control systems
• that manage die casting operations. This includes overseeing automation systems, troubleshooting issues, and
• optimizing the performance of machines used in the die casting process, including die casting machines, furnaces,
• robotic arms, conveyors, and cooling systems.

DUTIES AND RESPONSIBILITIES

• Design and implement control systems for die casting machines and associated automation equipment,

ensuring smooth operation and integration with other systems.

• Program, configure, and troubleshoot PLCs (e.g., Allen-Bradley, Siemens) that control key functions in the die

casting process, such as metal injection, mold ejection, cooling, and part handling

• Develop and maintain Human-Machine Interfaces (HMIs) for operators, providing a user-friendly interface to

monitor and control the die casting process.

• Integrate the die casting control systems with other plant equipment and systems such as material handling,

robot arms, and production line machinery.

• Continuously analyze the performance of die casting systems and recommend improvements to optimize

cycle time, reduce waste, enhance quality, and increase productivity.

• Continuously analyze the performance of die casting systems and recommend improvements to optimize

cycle time, reduce waste, enhance quality, and increase productivity.

• Provide on-site troubleshooting and technical support for issues related to control systems, including PLCs,

HMIs, sensors, and actuators.

• Ensure that control systems comply with safety standards (e.g., ISO, OSHA, NFPA) and implement safety

protocols to protect personnel and equipment.

• Collect and analyze process data to identify trends, root causes of problems, and opportunities for

improvement. Provide detailed reports and recommendations to management.

• Work closely with mechanical, electrical, and process engineers to optimize die casting operations and ensure

seamless integration of control systems with machinery.

• Train operators and maintenance staff on the operation and troubleshooting of control systems. Provide

ongoing technical support for new system upgrades or changes.

• Maintain detailed records of control system designs, configurations, and changes. Create standard operating

procedures (SOPs) for system operations and troubleshooting.

QUALIFICATIONS

MINIMUM REQUIRED

• High School Diploma
• 3+ years of experience in the following:

• o Allen Bradley Compact/ Control/ Guard Logix PLCs
• o Allen Bradley Panel Views
• o HMI Development
• o ABB and Fanuc robots
• o Welding, Riveting, Flow drill screws, Lasers, and other joining process controllers
• o Communications protocols: Ethernet/IP, ControlNet, Devicenet
• o PC setup - software and hardware configuration

• Proven experience in control systems engineering, preferably in manufacturing or die casting industries.
• Familiarity with die casting processes and machinery is a significant advantage.
• Automotive experience

PREFERRED

• Bachelor’s degree in electrical or mechanical engineering with prior controls and electrical work background
• Experience designing, building, and wiring industrial controls cabinets
• Stamping press line automation experience preferred - FOL de-stacking, washer/oiler, centering systems, inter

press, and conveyor systems

• Software: AutoCAD, Autodesk Inventor, and experience working with 30 CAD models
• Experience with Visual Basic, Visual C++, or other programming languages

WORK CONDITIONS

• Exposure to loud noises
• Stand, walk, sit, use hands, reach & grasp, climb, stoop, kneel, crouch, climb, talk & vision, lift up to 30lbs