Controls Engineer

Job Summary:

Assists with the development of all aspects of control systems, equipment, and machinery.

Key Responsibilities:

Assists with the development and design of control systems; assists with the development and implementation of bench tests; alters software and equipment to ensure that sensors and actuators are functioning according to specifications; supports and debugs basic problems and change requests. Assists with the preparation of cost estimates; compiles required cost and equipment information, and drafts appropriation requests. Investigates problems and requirements of projects, and develops plans for solutions in line with economic, personnel, and environmental considerations for review by more experienced Controls Engineers or Controls Engineering Manager. May be responsible for the installation and technical support of Programmable Logic Controller (PLC) based hardware and software. ResponsibilitiesCompetencies:
Collaborates - Building partnerships and working collaboratively with others to meet shared objectives.
Communicates effectively - Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences.
Health and Safety Fundamentals - Champions and models proactive health and safety behaviors by identifying, reporting and participating in actions to improve health and safety in order to build an interdependent culture and contribute to an injury-free workplace.
Controls Engineering Knowledge - Applies the application of controls hardware and software by specifying, reviewing, and approving company-owned and/or supplier designs for new or upgrades to existing equipment to interface with all levels of manufacturing systems.
Controls Networking - Implements new and improved technologies and methods capable of transferring information from multiple inputs either within a local production process or into databases to link machines together or to analyze the process for overall operation enhancements.
Controls Safety - Recognizes controls related hazards in a manufacturing environment (Electrical, Hydraulic, Pneumatic) to incorporate safe practices and procedures as part of the daily work plan to reduce injuries and create a safe machine environment.
Controls System Security - Develops and implements Controls System Security by specifying, reviewing, and approving company-owned and/or supplier designs for new equipment or upgrades to existing equipment to ensure our manufacturing controls and systems are secure.
Electrical System Troubleshooting - Analyzes an electrical control system to resolve and repair electrical issues to return the system to proper operating conditions.
Factory Automation and Control Systems - Implements changes to further automate manufacturing processes using available technology, programming techniques, and identifying needed material and resources for project completion to provide the optimum automation for the manufacturing environment.
Sensor Technology and Measurement - Selects and applies the sensor technology, performing measurements in the acquired data that leads to the correct analysis and conclusion to help differentiate products that meet quality standards from non-conforming products.
Values differences - Recognizing the value that different perspectives and cultures bring to an organization.
Manufacturing Knowledge - Demonstrates the knowledge of manufacturing by correctly implementing changes in current processes, equipment, and applications to meet the function's needs and contribute towards continuous improvement.
Machine Programming - Creates factory floor machine programs by designing and implementing solutions to improve usage of machine and overall operation.
Education, Licenses, Certifications:
College, university, or degree in STEM (Science, Technology, Engineering, Math) or related field, or equivalent experience required.
This position may require licensing for compliance with export controls or sanctions regulations.
Experience:
Basic level of relevant experience required. QualificationsMechatronics Control Engineer Profile as per CNC/ PLC & Robotics for CNC Machine shopCNC / PLC - HMC Machines.
( Sinumeric -1 / Siemens 840 D/ 828D /   810D /Fanuc 0i / Beckhoff etc. / TIA Portal / GX works /)
MAG - Spect 800 HMC
Gudel GantryElectrical panel health check review & and ensure panel & field wiring must be in good condition. Battery details & replacements management.CNC controller backup (Siemens/Fanuc / Beckhoff etc.) with Upload/download / Editing   upgrades of  CNC maintenance related programmes. CMES communicationServo/spindle drive, VFDs maintenance and parameters backup maintains. - S120 / G120 / V90 / AB, Micro master, Mitsubishi VFDs, Festo servo suites, TOX servo press drives etc.Axis encoder, Linear scale and rotary encoders feedback checks. Homing , referencing and Backlash checking and corrections, including pitch error compensations, tunning & others relevant.Signal tracing for interlocks and faults and Parameters etc. IO module configurations and able to add / updates.CBM, Preventive maintenance, Autonomous maintenance.PLC Systems / TIA Portal
(Siemens,Mitsubishi,Beckhoff etc.)
 Industrial IPC - Advantech MakeUpload/download / Editing  upgrades of  PLC programs, CMES communication, Handshaking with 3rd party devicesIPC troubleshooting, IO faults finding PLC progg developments.Able to work on IPC - mostly Advantech make  - Comple Backup upload , download and ghost image backups and trouble shooting, and integration with other device and IO monitors.Signal simulation for diagnostics of faults wrt to current cycles.Communication troubleshooting, ProfiNet, Profibus, Ethernet/IP and others.Safety relay & emergency circuit testing, troubleshooting and monitoring. In PLC as well as in Hard wires.Fanuc Robots, Cobots & AMR/AGV -
Cylinder Block & Head handling Fanuc - Robot controller maintenance, PM  etc. / Able to work on Fanuc Robo guide & Zero downtime, OPC UA communications.Program backup & restore and editing.Mastering & zeroing, Teaching, referencing, Tuning etc.Encoder battery monitoring and replacements.Hands on experience on AMRJoint motor current & speed analysis, temperature monitoringEnsure safety features activation and monitoring and improvements / Virtual fencing / IO monitoring etc.Preventive lubrication & cleaning and CBMs, Handshaking with other Machines , CMES communicationGantry Systems (e.g., Güdel)Gantry axis drive monitoring, CMES Integration, 3rd party communications.Encoder & linear scale feedback checks and repairs & replacements with parameterisations.EStop circuit integration with CNC and monitoring.Positioning error diagnostics and corrections as per actual needsSoftware interface with CNC via PLC and 3rd party devices.Safety & InterlocksInterlock logic verification with PLC/HMIEmergency stop mapping with I/O and safety PLC progg. , can able to add / updates.Light curtain and safety relay use, monitor and add/update according to process requirements.Documentation & BackupMaintain log of breakdowns & solutions - Maximo , Sap and Excel and Log books.Preventive maint. Execute as per plan and update check sheet with findings.Why why analysis done on regular basis for major  & repetitive issues.Failsafe check list developed and maintain it.SOP, FMEA developments for train the sub ordinates.Follow the Cummins HSE safety std. and LOTO GuidelinesPrepare documentation for Audit - readiness, MIS documentationsMaintain all Software's upto dates.Able to read electrical, Hyd. , Pneumatic and coolant ckt . Diagrams.On regular frequency  need to take  all   controller/PLC/robot software   machine backup regularly - with Ghost & Image backups.Required education & Experience with Working environments :Ability to work in required shifts and overtime as required. with self motivated and positive attitude. Can able to coach others team members.Physical ability to lift heavy machinery components and perform tasks in confined spaces.Experience: 10-12 years of hands-on Mechatronics maintenance experience, specifically with CNC machines, preferably HMCs.Education: Technical diploma / degree or certification in mechatronics engineering, industrial maintenance, or a related field.        Spares Parts Planning as per Each machine and procure timely , with ensure good inventory as per AOP budgets.Machine Manuals - Electrical , Mechanical, and others documentations - Must maintain in soft & hard copies.Maintenance Tools upkeep and maintain to use on need and do audit and top-ups the broken tools.Ensure zero Leakage in Plant equipment's.Explore opportunity for energy and cost Saving.Localization for High value and high lead time spares parts.Initiate for local repairs.Familiar with Cylinder block and head manufacturing - HMC/ gantry / Nagel honing / Final Washing / Torquing application / Leak test  / Laser mark / ball screw replacement / tables maintenance etc.About UsCummins is an equal opportunity employer. Our policy is to provide equal employment opportunities to all qualified persons without regard to race, sex, color, disability, national origin, age, religion, union affiliation, sexual orientation, veteran status, citizenship, gender identity, or other status protected by law.