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The Controls Engineer is responsible for designing, programming, commissioning, and supporting automation and control systems used in the manufacturing of lithium-iron battery and energy storage products. This role requires a hands-on engineer capable of independently troubleshooting complex automation systems in a fast-paced manufacturing environment. This role ensures production equipment operates safely, reliably, and efficiently while supporting continuous improvement, new equipment integration, and plant automation initiatives.
The Controls Engineer collaborates with manufacturing engineering, equipment vendors, quality, EHS, and operations teams to implement robust automation solutions that improve throughput, quality, and uptime.
KEY RESPONSIBILITIES:
Automation & Controls Development
- Design, program, and troubleshoot PLC-based control systems for automated manufacturing equipment
- Develop and troubleshoot Mitsubishi HMI systems (GT Designer / GOT)
- Configure HMI / SCADA systems for machine monitoring, diagnostics, and operator interface.
- Integrate robotics, vision systems, and automated material handling equipment into production environment processes.
Equipment Integration & Commissioning
- Lead controls design, installation, and commissioning of new manufacturing equipment.
- Collaborate with equipment vendors and integrators during factory acceptance testing (FAT) and site acceptance testing (SAT).
- Develop controls standards and documentation for plant automation systems.
Manufacturing Support
- Provide technical troubleshooting support for production equipment downtime related to controls, sensors, drives, and automation.
- Work closely with maintenance and production teams to diagnose and resolve automation issues.
- Optimize control strategies to improve cycle time, reliability, and equipment uptime.
- Support 24/7 production operations and provide rapid troubleshooting of automation issues impacting plant throughput
- Identify root causes of recurring automation issues and implement long-term corrective actions
Safety & Compliance
- Design and validate machine safety systems including safety PLCs, interlocks, emergency stops, and safeguarding systems.
- Ensure equipment complies with OSHA, NFPA, NEC, and all relevant machine safety standards.
- Support high-voltage and lithium-iron manufacturing safety requirements.
Process Optimization
- Analyze equipment performance data to identify automation improvements and efficiency gains.
- Implement process automation improvements to increase throughput and reduce scrap.
- Support continuous improvement initiatives and plant automation roadmaps.
Documentation & Standards
- Maintain detailed documentation including:
- PLC, HMI, and Safety code revisions
- Electrical schematics
- Controls Network architecture
- Automation standards & specifications
· Support development of plant-wide automation and controls standards.
The ideal candidate will possess the following skills:
- Strong hands-on experience with Mitsubishi PLC platforms (GX Works / GX Works 2 & 3 / iQ-R / Q-Series)
- Experience integrating PLC systems with MES / production database systems
- Understanding of PLC–MES handshake protocols, data validation, and traceability systems
- PLC programming
- Mitsubishi (GX Works, GT Designer)
- Allen Bradley (Studio 5000 / RSLogix)
- Diagnosing and troubleshooting industrial control networks including Ethernet/IP, CC-Link, Profinet, and TCP/IP infrastructure
- HMI/SCADA systems
- Servo systems and VFD drives
- Robotics integration (Fanuc, ABB, Kuka, or similar)
- Machine vision systems
- Electrical schematics and panel design
- Industrial sensors and instrumentation
The ideal candidate will be able to demonstrate the following preferred experience:
- EV battery, lithium-iron, semiconductor, or high-tech manufacturing
- Dry-room or clean-room manufacturing environments
- Industrial Manufacturing Production – Automotive, EV, Injection Molding, Food/Beverage, etc.
- High-speed automated production lines
- Safety PLCs and machine safety standards (ISO 13849 / NFPA)
- Six Sigma Leadership
The following competencies are desired:
- Ability to independently diagnose complex automation problems across PLC, HMI, robotics, and industrial networking systems
- Systems integration and commissioning
- Cross-functional collaboration
- Cross-cultural & organizational collaboration
- Continuous improvement mindset
- Strong technical documentation skills
- Ability to support a fast-paced manufacturing environment
QUALIFICATIONS:
- Bachelor's Degree in Mechanical Engineering or related field
- Strong hands-on experience with Mitsubishi PLC platforms (GX Works / GX Works 2 & 3 / iQ-R / Q-Series)
- Experience developing and troubleshooting Mitsubishi HMI systems (GT Designer / GOT)
- Allen-Bradley PLC experience considered a plus
- Experience supporting automated production lines or industrial equipment
- Experience with PLC programming and industrial automation systems
Our Next Energy Inc. (ONE) is an equal opportunity employer and is committed to providing equal employment opportunities to all employees and applicants without regard to disability or any other protected status in accordance with applicable federal, state, and local laws.
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