Controls Engineer

Job description

**Job Purpose** Engineer – ME Controls is responsible for designing, developing, & implementing advanced automation & control systems for Dana TM4’s EV powertrain manufacturing lines. The role involves SCADA architecture, MES integration (IoT 4.0), PLC programming, PCB design & failure analysis, & high-voltage/low-voltage motor assembly line controls. The position ensures robust, scalable, & compliant control solutions for inverter & motor production, driving Industry 4.0 readiness, process optimization, & zero-defect manufacturing. **Job Duties And Responsibilities** - SCADA Development: Design & deploy SCADA systems for real-time process monitoring, alarms, & data acquisition. - MES & IoT 4.0: Implement MES solutions integrated with IoT sensors for predictive maintenance & digital twin applications. - PLC Programming: Develop ladder logic & structured text programs for Siemens, Allen-Bradley, & Beckhoff PLCs; ensure fail-safe operations. - PCB Design & Testing: Create PCB layouts for control circuits, perform functional testing, & conduct root cause analysis for failures. - High-Voltage Safety: Design interlocks & safety circuits for HV motor assembly lines; ensure compliance with IEC & Dana standards. - Automation Projects: Lead end-of-line automation projects, including robotic integration & vision systems for quality assurance. - Data Analytics: Utilize Python/MATLAB for process data analysis & KPI dashboards for OEE improvement. - Cross-Functional Collaboration: Work with design, quality, & production teams to support EV inverter & motor NPD (New Product Development). **Education And Qualifications** - Diploma/Degree in Electrical/Electronics/E&TC Engineering. - Hands-on experience in automation & controls engineering for EV manufacturing. - Proficiency in PLC, SCADA, MES, & IoT integration. - Knowledge of embedded systems & wiring harness programs. - Strong analytical, troubleshooting, & documentation skills. ****Skills and Competencies**** - Advanced SCADA & MES Architecture - PLC Programming (Siemens TIA Portal, Allen-Bradley RSLogix) - PCB Design & Failure Mode Analysis - High-Voltage Motor Assembly Line Controls - Embedded Systems & Arduino Prototyping - IPC Wiring Harness Standards - Data Analytics & Predictive Maintenance - Industry 4.0 Implementation & Digital Manufacturing