Controls Engineer
Job Description
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
