Manufacturing Controls & Integration Engineer

Position Title:                Manufacturing Controls & Integration Engineer                     FLSA Status:       Exempt

Reports To:                     Continuous Improvement Manager

Scope:                              Drive equipment integration and process optimization across the plants by combining PLC/HMI controls, CAD-driven design, machine build/fabrication coordination, and structured root-cause analysis. Partner with EHS, Quality, Operations, Maintenance, and Product Development to increase throughput, cut waste, and improve safety and quality using Lean/CI methods and robust documentation (SOPs, work instructions).  

Essential Duties:

Controls / Automation

· Program, modify, and troubleshoot PLCs (primarily ladder logic), HMIs, VFDs, and supporting I/O; integrate sensors, vision, pneumatics, and hydraulics into reliable machine controls.

· Lead controls changes for equipment launches and upgrades; validate cycle times and interlocks; document logic changes.

Machine Integration & Fabrication

· Specify, select, and layout equipment; coordinate build/integration with internal fabrication or vendors (mechanical, electrical, pneumatic, hydraulic).

· Read/create mechanical and electrical prints; oversee assembly, tryout, FAT/SAT, and handoff to production.

· Fabricate tooling, fixtures, jigs, and machine components in-house—using welding, metal/plastic fabrication, and general shop equipment—to expedite work when needed.

CAD & Documentation

· Use AutoCAD to produce/update electrical schematics, panel layouts, machine prints, and plant layouts.

· Create, publish, and maintain SOPs, work instructions, PFMEAs, process flows, and manufacturing plans.

Root-Cause Analysis & Continuous Improvement

· Lead A3/8D problem solving, 5-Why, and PDCA; analyze downtime and scrap to eliminate losses and improve OEE.

· Conduct Gemba walks; participate in Kaizen events to improve safety, quality, increase capacity, and reduce cost.

Cross-Functional Partnership

· Collaborate with Quality/EHS on risk and compliance; with Operations on rates/simulations; with Product Development on DFM and launch readiness; with Maintenance on reliability/PM.

· Train operators/technicians on equipment and best practices.

Project Execution

· Scope, plan, and execute multiple projects in a fast-paced environment; report progress, timelines, and results.

Requirements & Qualifications:

· AS/BS in Electrical, Mechanical, Manufacturing, Industrial, or related field; or equivalent experience.

· 2+ years in controls/integration and manufacturing/industrial engineering.

· Technical: PLC ladder logic (e.g., Allen-Bradley, Siemens), HMI development, VFDs; electrical/mechanical aptitude; pneumatics/hydraulics; CAD proficiency (AutoCAD required; 3D CAD a plus); data analysis.

· Hands-on fabrication ability: welding and metal/plastic fabrication to build tooling, fixtures, and components in-house; safe shop practices.

· CI/RCA: Familiar with Lean, 5S, A3/8D, PDCA; Six Sigma Yellow Belt a plus.

· Soft Skills: Strong communication, training, and teamwork; ability to juggle multiple projects and meet deadlines.

· Experience evaluating and troubleshooting manufacturing processes and machinery.

· Knowledge of equipment for purchase, installation, and repair

· Demonstrated leadership skills and ability to contribute solutions on multiple ongoing projects.

· Ability to work independently and handle multiple projects at the same time with limited supervision, excellent planning, time management and decision-making skills.

· Strong motivation, level disposition, work ethic, leadership, and organizational skills.

· Excellent work history, attendance, initiative and drive to succeed.

· Maintain excellent communication and relationships with others; be a team player; maintain a positive attitude.

· Perform in a manner consistent with Uckele Company Vision/Mission Statement and Core Values.