Controls Engineer

As an Automation & Controls Engineer, you will be a key member of the Advanced Technology Platform (ATP) Organization within the Automation and Controls Engineering (ACE) division. In this role, you will lead and support controls automation activities and deliverables across Powertrain (PTME), Vehicle (VME), and Battery (BME) Manufacturing Engineering programs. Your responsibilities will span the entire manufacturing lifecycle—from implementing cutting-edge technologies and innovation to managing equipment obsolescence, ensuring quality, safety, cybersecurity, and providing troubleshooting manufacturing support for Ford’s global plant operations.

As an Automation & Controls Engineer, you will be the technical bridge between design and execution, ensuring our manufacturing lines are intelligent, efficient and engineered to the highest safety and quality standards. You will play a pivotal role in the entire program lifecycle—from initial studies and equipment design to machine build, installation, and final launch. 

Key Responsibilities and Contributions:

• End-to-End Program Leadership: You will estimate, plan, and deliver comprehensive controls deliverables for PTME and VME programs. This includes managing the "Runoff-Buyoff" process, completing Machine Acceptance Checklists, and ensuring all equipment complies with Ford’s specifications and standards.

• Technical Design & Integration: As a lead for integration teams, you will conduct detailed reviews of electrical, hydraulic, and pneumatic drawings. You will coordinate Virtual Commissioning with Global Vehicle Product Engineering (GVPE) and manage the interface between software applications and OEM integrations.

• Operational Excellence & Troubleshooting: You will be the "boots on the ground" for issue resolution during machine build and installation. Your expertise will be vital in troubleshooting complex production-related downtime (PLC/HMI) and managing change controls post-launch to maintain system stability.

• Strategic Infrastructure & Cybersecurity: You will lead the coordination of power requirements for manufacturing assets and serve as the point of contact for plant-floor cybersecurity. You will ensure compliance with all CPN and MPN networks, protecting our manufacturing ecosystem from digital vulnerabilities.

• Data & Systems Management: You will maintain critical program documentation within Ford systems such as MIDAS, OPIC, and PROTAG. This includes overseeing 10-panel/15-panel deliverables and ensuring all Manufacturing IT interfaces (such as IIOT, QTS/QLSCM, Octoplant, QWX, WMA and Q-DAS) are seamlessly integrated.

• Business & Procurement Stewardship: You will support and lead the enquiry specification process (ESWP/SPA), managing risk assessments, Bill of Materials (BOM), and the purchasing process from initial PO generation to final invoice payment.

• Innovation: Driving the deployment of Smart Factory strategies and integrating "Launch Enablers" like machine monitoring and advanced quality systems.

To be successful in this role, you must possess a blend of technical engineering expertise, project management skills, and a proactive approach to problem-solving in a fast-paced manufacturing environment.

Basic Qualifications:

• Education: Bachelor’s degree in Mechanical, Mechatronic, or Electromechanical Engineering.

• Experience: Minimum of 2 years of experience in developing manufacturing processes.

• Communication: Excellent professional English proficiency (oral and written) to collaborate with global teams.

• Travel & Compliance: Must have a valid Passport and U.S. Visa available for international collaboration and training.

• Availability: Flexibility to work extended hours as required to meet program launch milestones.

Technical Skills & Knowledge:

• Core Engineering Fundamentals: Strong knowledge of power distribution, electrical systems, pneumatics, and hydraulics.

• Programming Proficiency: Proficiency in PLC programming languages including Ladder Logic (LD/LAD), Instruction List (IL), and Structured Text (ST/SCL).

• Safety Engineering: Experience with safety programming, Risk assessments, safety circuits, and the integration of safety devices such as light curtains, interlocks, e-stops and area scanners.

• Control Systems: Knowledge and experience with Rockwell AB/Siemens PLCs, HMIs, Drives, CNCs and Communication Protocols (EtherNet/IP, PROFINET, and IO-Link). Traceability Systems (e.g. RFID, vTAG, UHF)

• Robotics: Familiarity with Fanuc, ABB, and Cobot integration.

• Vision & Nutrunner Systems: Experience with Vision Systems (Cognex, Keyence) and Nutrunner systems (Atlas Copco).

• Specialized Machinery: Knowledge of Press Systems, Laser, Testing, others (e.g., Promess, Trumpf) 

• Standards & Procedures: Familiarity with Quality Standards, Equipment Acceptance procedures (PTME), and Safety Documentation.

• Administrative Proficiency: Experience in generating Purchase Orders, following up on invoices, and Project Management.

Soft Skills:

• Strong organizational and time management skills with the ability to prioritize multiple tasks.

• Proven problem-solving abilities and a collaborative mindset for working across multi-functional teams.

• Ability to manage "Lessons Learned" to continuously improve engineering standards and architectures.