Controls EngineerLocation: Warren, Michigan, United States
Industry: Automotive Manufacturing
Role Type: Controls / Automation / MES Engineering
Position OverviewWe are seeking an experienced Controls Engineer to support a ground-up manufacturing automation implementation for a
major automotive manufacturer in Warren, Michigan.
This is primarily a
new-build development and implementation role, not a sustaining or maintenance position. The engineer will be responsible for designing, programming, integrating, and commissioning controls and manufacturing systems, with a strong focus on
Rockwell Studio 5000, Ignition, and PLC-to-MES integration.
The ideal candidate has personally taken automation systems from initial design through commissioning and production launch and can demonstrate hands-on experience developing PLC, HMI/SCADA, and MES functionality rather than only modifying or troubleshooting existing systems.
Key Responsibilities- Design and develop Allen-Bradley ControlLogix/GuardLogix PLC programs from the ground up using RSLogix 5000 / Studio 5000.
- Develop PLC architecture including ladder logic, tag structures, UDTs, AOIs, sequencing, diagnostics, alarms, and equipment interfaces.
- Design and build Ignition HMI/SCADA applications, including screens, tags, scripting, alarms, communications, and system configuration.
- Develop and implement communication between PLCs and MES systems.
- Create PLC/MES transaction and handshake logic for manufacturing operations.
- Support work-order verification, part and serial-number traceability, recipe/model management, production reporting, and pass/fail transactions.
- Integrate barcode scanners, RFID systems, and other production tracking equipment.
- Configure and integrate Zebra industrial label printers, including generation and implementation of ZPL code.
- Develop automated label-printing processes tied to production events, work orders, and cycle completion.
- Perform controls system startup, debugging, commissioning, FAT/SAT, and production launch activities.
- Troubleshoot PLC, HMI, MES, networking, and equipment communication issues as needed.
- Collaborate with manufacturing engineering, IT/MES teams, equipment integrators, and plant personnel throughout implementation.
- Develop and maintain controls documentation, system architecture, backups, and commissioning records.
Required Qualifications- Strong hands-on experience with Allen-Bradley ControlLogix/GuardLogix and Studio 5000 / RSLogix 5000.
- Demonstrated experience writing new PLC programs for equipment, stations, or production lines from scratch.
- Hands-on experience with Inductive Automation Ignition.
- Experience developing Ignition screens, tags, scripting, and/or application architecture.
- Experience integrating PLCs with MES or manufacturing information systems.
- Understanding of manufacturing transactions such as work-order validation, traceability, recipes, production reporting, and serial-number tracking.
- Experience commissioning automated manufacturing equipment.
- Strong troubleshooting skills across controls hardware, PLC software, industrial networks, and production systems.
- Experience in automotive or other high-volume discrete manufacturing environments.
Preferred Qualifications- Experience generating ZPL code and integrating Zebra industrial printers.
- Experience with barcode and RFID-based production traceability.
- Ignition Vision and/or Perspective development experience.
- Industrial networking experience including Ethernet/IP, OPC UA, SQL, or related communication technologies.
- Experience taking a controls project through the complete lifecycle: design development integration startup commissioning production launch.
- Bachelor's degree in Electrical Engineering, Controls Engineering, Mechatronics, Automation, Industrial Engineering, or a related discipline.
Ideal CandidateThe strongest candidate will have experience
building controls systems from the ground up, including PLC programming, Ignition development, and PLC-to-MES integration.
This position is best suited for an engineer who has built and commissioned new manufacturing systems rather than someone whose background is primarily production support or maintenance.
North Point Technology is
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