Location: Chennai, Tamil Nadu
Department: Manufacturing
Ford Powertrain Manufacturing is seeking a skilled and hands-on Controls Engineer with 3 to 10 years of experience in a high-volume manufacturing environment.
The role is responsible for improving, troubleshooting, validating, and supporting plant floor control systems, automation equipment, robotics, CNC/machining systems, data collection platforms, error-proofing systems, and industrial networks.
The successful candidate will work closely with production, maintenance, process engineering, safety, IT, suppliers, and plant leadership to improve equipment uptime, support engineering changes, resolve chronic downtime issues, and ensure robust controls integration across Ford Powertrain operations.
Responsibilities
Controls Engineering and Equipment Support
- Develop, implement, and sustain improvements to manufacturing control systems, automation equipment, and production processes.
- Troubleshoot PLC, CNC, robot, vision, motion control, safety, and industrial network issues to reduce downtime and improve equipment reliability.
- Lead or support structured problem solving for equipment performance issues, including root cause analysis, validation of fixes, and recurrence prevention.
- Modify, debug, and validate control logic for engineering changes, process improvements, product changes, and quality initiatives.
- Maintain current and accurate program backups for PLCs, robots, CNC systems, HMIs, drives, and related automation equipment.
Powertrain Manufacturing Systems Integration
- Support integration of plant floor controls with Ford manufacturing systems such as FIS, QWX, QTS, error-proofing systems, WMA, OBL, SMART, VTAG, GPTS, IIoT, and related applications.
- Use Factory Information Systems and plant monitoring tools to analyze cycle time, downtime, throughput, fault history, and equipment performance trends.
- Support integration of CNC controls, gantries, auxiliary equipment, RFID systems, traceability systems, and complexity management solutions.
- Validate PLC logic, station numbering, data collection, Andon functionality, error-proofing logic, and communication interfaces.
Project Launch and Installation Support
- Review and coordinate controls-related activities for equipment installations, upgrades, commissioning, and launch support.
- Participate in controls design reviews, risk assessments, machine safety reviews, and project readiness reviews.
- Support cost study, design, build, debug, installation, commissioning, launch, and production ramp-up phases.
- Work with internal teams, equipment suppliers, and system integrators to ensure controls deliverables meet Ford standards and plant operational requirements.
- Support virtual commissioning activities when applicable to validate control logic and software before physical installation.
Operational Excellence and Continuous Improvement
- Apply lean manufacturing, Six Sigma, 8D, FMEA, DMAIC, 5S, Kanban, Poka-Yoke, Kaizen, and value stream improvement methods to support manufacturing performance.
- Use industrial engineering concepts such as constraint analysis, cycle time analysis, and productivity improvement to optimize system throughput.
- Capture lessons learned and provide feedback to improve controls standards, component selection, equipment maintainability, and future program execution.
- Support standardization of controls practices, machine safety processes, useful life planning, and deviation management.
Cross-Functional Collaboration and Training
- Collaborate effectively with production, maintenance, plant electricians, process engineering, safety, IT, quality, suppliers, and plant leadership.
- Assist in training manufacturing personnel, maintenance teams, and electricians on controls systems, troubleshooting methods, and safe equipment operation.
- Communicate technical issues, risk items, recovery plans, and improvement opportunities clearly to technical and non-technical stakeholders.
- For candidates at the higher end of the experience range, provide technical guidance, coaching, and informal mentorship to junior engineers and plant technical teams.
Qualifications
Required Qualifications
- Bachelor’s degree in Electrical Engineering, Electronics Engineering, Instrumentation Engineering, Controls Engineering, Automation Engineering, Mechanical Engineering, Mechatronics, or a related discipline.
- 3 to 10 years of controls engineering experience in a manufacturing, powertrain, automotive, machining, assembly, or industrial automation environment.
- Hands-on experience troubleshooting and modifying PLC logic, HMI screens, automation systems, robots, drives, sensors, actuators, and industrial communication systems.
- Experience with one or more PLC platforms such as Siemens, Rockwell/Allen-Bradley, Bosch, or equivalent industrial control systems.
- Working knowledge of robotic systems such as ABB, FANUC, or similar industrial robots.
- Ability to read and interpret electrical, pneumatic, hydraulic, controls, and automation prints.
- Understanding of industrial communication networks, fieldbus protocols, and plant floor data interfaces.
- Proficiency with Microsoft Office applications including Word, Excel, PowerPoint, and Outlook.
Preferred Qualifications
- Experience in Ford Powertrain manufacturing, machining lines, engine, transmission, eDrive, battery, or propulsion system manufacturing.
- Experience with CNC controls, machining cells, gantries, transfer systems, assembly lines, torque systems, and auxiliary automation equipment.
- Knowledge of Factory Information Systems, IIoT, error-proofing, QWX, QTS, WMA, OBL, SMART, VTAG, GPTS, QDAS, PDS, or similar manufacturing IT systems.
- Experience with vision systems such as Keyence, Cognex, Zebra, or equivalent inspection and traceability systems.
- Knowledge of RFID systems, traceability, complexity management, scheduling logic, and quality operating system strategies.
- Understanding of international and regional electrical and machine safety standards, including UL, ISO, IEC, risk assessments, PSS, and integrated safety systems.
- Experience with GPDS or equivalent program delivery processes, equipment launch, and manufacturing readiness deliverables.
- Lean Manufacturing, Six Sigma, 8D, FMEA, DMAIC, TQM, and Kaizen experience.
