We are looking for a talented Sr. Controls Engineer to join our team specializing in Manufacturing for our Cummins Drivetrain and Braking Systems Facility, in Morristown, TN.
The Sr. Controls Engineer develops all aspects of control systems, equipment, and machinery.
In this role, you will make an impact in the following ways:
- Lead the design, development, and implementation of PLC-based control systems that improve equipment reliability, manufacturing performance, and operational efficiency.
- Troubleshoot and resolve complex controls, automation, and software issues to minimize downtime and ensure critical production systems operate at peak performance.
- Develop and execute testing and validation plans that verify sensors, actuators, and control systems meet design specifications before deployment.
- Drive continuous improvement by modifying control logic, software, and equipment configurations to enhance safety, quality, productivity, and system capability.
- Deliver cost-effective automation solutions by developing project budgets, preparing capital appropriation requests, and ensuring investments generate measurable business value.
- Analyze manufacturing challenges and operational requirements to develop innovative solutions that balance technical, economic, environmental, and workforce considerations.
- Support the installation, startup, and optimization of PLC hardware and software systems, ensuring seamless integration into manufacturing operations.
- Mentor and develop less experienced Controls Engineers by sharing technical expertise, strengthening problem-solving capabilities, and building organizational controls engineering capability.
Responsibilities
To be successful in this role you will need the following:
Build strong cross-functional partnerships by working closely with Operations, Maintenance, Manufacturing Engineering, Quality, IT, and equipment suppliers to deliver automation solutions that support business objectives.
Communicate technical concepts effectively by translating complex controls, networking, and automation requirements into clear, actionable information for operators, technicians, leaders, and project stakeholders.
Lead with safety as the top priority by identifying electrical, hydraulic, pneumatic, and machine-control risks and incorporating appropriate safeguards, lockout/tagout requirements, and safe machine design principles into every project.
Demonstrate strong controls engineering expertise by designing, reviewing, and implementing PLC, HMI, sensor, and automation systems that reliably integrate with manufacturing equipment and enterprise systems.
Leverage controls networking and system security knowledge to ensure manufacturing equipment communicates effectively while protecting control systems from cyber and operational risks.
Excel at troubleshooting and root cause analysis by quickly diagnosing electrical, controls, and automation issues, restoring equipment performance, and implementing permanent corrective actions to prevent recurrence.
Drive factory automation and continuous improvement by identifying opportunities to increase productivity, improve quality, reduce downtime, and optimize manufacturing performance through advanced automation technologies.
Apply manufacturing knowledge to deliver business results by developing machine programs, selecting appropriate sensor technologies, supporting process improvements, and implementing solutions that improve safety, quality, delivery, and cost performance.
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:
- Intermediate level of relevant work experience required.
Additional Requirements:
Must have extensive experience in Allen Bradley and Siemens
Background in safety as it relates to automation and automated cells
Extensive knowledge of Fanuc robots
Ability to design, program, and commission automated cells
Skills Required
- College or university degree in STEM or a related field, or equivalent experience
- Intermediate level of relevant work experience
- Extensive experience with Allen Bradley and Siemens systems
- Background in safety as it relates to automation and automated cells
- Extensive knowledge of Fanuc robots
- Ability to design, program, and commission automated cells
Cummins Compensation & Benefits Highlights
The following summarizes recurring compensation and benefits themes identified from responses generated by popular LLMs to common candidate questions about Cummins and has not been reviewed or approved by Cummins.
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Retirement Support — A 401(k) with company contribution/match and both defined contribution and defined benefit pension plans are offered, alongside profit sharing and an employee stock purchase plan. This mix supports long-term savings and financial security.
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Healthcare Strength — Multiple medical plan options (HSA, HSA Plus, PPO) with dental, vision, life and long-term disability coverage are provided, along with telehealth, mental-health support, and wellness tools. In-network protections and HSA/HSA Plus structures are described to help manage costs.
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Parental & Family Support — Paid maternity and paternity leave, family medical leave, and adoption assistance are offered. Reduced or flexible hours and unpaid extended leave options further support caregiving needs.
Cummins Insights
What We Do
At Cummins, we empower everyone to grow their careers through meaningful work, building inclusive and equitable teams, coaching, development and opportunities to make a difference. Across our entire organization, you'll find engineers, developers, and technicians who are innovating, designing, testing, and building. You'll also find accountants, marketers, as well as manufacturing, quality and supply chain specialists who are working with technology that's just as innovative and advanced.
