Controls Engineer in Cassopolis

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Job DescriptionJob Description

Position Summary

The Controls Engineer is responsible for designing, maintaining, troubleshooting, and improving control systems supporting aluminum extrusion operations. This role ensures safe, reliable, and efficient operation of extrusion presses, billet handling systems, aging ovens, quench systems, saws, and downstream equipment through effective PLC, HMI, and automation solutions.

Key Responsibilities

Controls & Automation

• Design, program, troubleshoot, and maintain PLC systems (Allen-Bradley ; Siemens a plus).
• Develop and support HMI/SCADA applications for extrusion presses and supporting equipment.
• Maintain and optimize control systems for extrusion presses, pullers, saws, billet heaters, quench systems, run-out tables, and aging ovens.
• Diagnose and resolve electrical, controls, and automation-related downtime issues.

Continuous Improvement

• Identify opportunities to improve uptime, safety, quality, and throughput through automation and controls enhancements.
• Support Lean, Six Sigma, and continuous improvement initiatives.
• Standardize control logic, documentation, and best practices across equipment.

Electrical & Instrumentation

• Support variable frequency drives (VFDs), servos, encoders, sensors, vision systems, and safety devices.
• Assist with electrical schematics, panel layouts, and I/O documentation.
• Ensure control systems comply with applicable safety standards (NFPA 70/79, OSHA, ANSI).

Project Support

• Lead or support controls scope for capital projects, retrofits, and equipment upgrades.
• Interface with OEMs, integrators, and vendors during installation and commissioning.
• Support new equipment start-ups and process changes.

Collaboration & Support

• Work closely with maintenance, operations, quality, and engineering teams.
• Provide training and technical support to maintenance technicians.
• Participate in on-call or off-shift support as required.

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Controls Engineering, or related field (or equivalent experience).
• 3+ years of controls engineering experience in a manufacturing environment.
• Hands-on experience with PLC programming and troubleshooting.
• Experience with HMI development and industrial networks (EtherNet/IP, ControlNet, Profibus, etc.).
• Strong understanding of industrial electrical systems and automation.

Qualifications

• Experience in aluminum extrusion, metals, steel, or heavy manufacturing.
• Allen-Bradley ControlLogix / CompactLogix experience.
• Experience with motion control, servo systems, and robotics.
• Knowledge of safety PLCs and machine safety design.
• Familiarity with data collection, MES, or OEE systems.

Skills & Competencies

• Strong troubleshooting and problem-solving skills
• Ability to work in a fast-paced, industrial environment
• Excellent communication and cross-functional collaboration
• Self-motivated with strong attention to detail
• Ability to manage multiple priorities and projects

Work Environment

• Manufacturing plant environment with exposure to heat, noise, and industrial equipment.
• Occasional lifting, climbing, and extended standing/walking.
• Off-shift or weekend support may be required during outages or startups.

Compensation & Benefits

• Competitive salary based on experience
• Medical, dental, vision insurance
• 401(k) with company match
• Paid time off and holidays
• Opportunities for growth and advancement

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