Location: Fort Wayne, Indiana, United States
Industry: Automotive Manufacturing
Role Type: Controls / Automation / MES Engineering
We are seeking an experienced Controls / MES Engineer to support a ground-up manufacturing automation implementation for a major automotive manufacturer in Warren, Michigan.
This is primarily a new-build development and implementation role, not a sustaining or maintenance position. The engineer will be responsible for designing, programming, integrating, and commissioning controls and manufacturing systems, with a strong focus on Rockwell Studio 5000, Ignition, and PLC-to-MES integration.
The ideal candidate has personally taken automation systems from initial design through commissioning and production launch and can demonstrate hands-on experience developing PLC, HMI/SCADA, and MES functionality rather than only modifying or troubleshooting existing systems.
Design and develop Allen-Bradley ControlLogix/GuardLogix PLC programs from the ground up using RSLogix 5000 / Studio 5000.
Develop PLC architecture including ladder logic, tag structures, UDTs, AOIs, sequencing, diagnostics, alarms, and equipment interfaces.
Design and build Ignition HMI/SCADA applications, including screens, tags, scripting, alarms, communications, and system configuration.
Develop and implement communication between PLCs and MES systems.
Create PLC/MES transaction and handshake logic for manufacturing operations.
Support work-order verification, part and serial-number traceability, recipe/model management, production reporting, and pass/fail transactions.
Integrate barcode scanners, RFID systems, and other production tracking equipment.
Configure and integrate Zebra industrial label printers, including generation and implementation of ZPL code.
Develop automated label-printing processes tied to production events, work orders, and cycle completion.
Perform controls system startup, debugging, commissioning, FAT/SAT, and production launch activities.
Troubleshoot PLC, HMI, MES, networking, and equipment communication issues as needed.
Collaborate with manufacturing engineering, IT/MES teams, equipment integrators, and plant personnel throughout implementation.
Develop and maintain controls documentation, system architecture, backups, and commissioning records.
Strong hands-on experience with Allen-Bradley ControlLogix/GuardLogix and Studio 5000 / RSLogix 5000.
Demonstrated experience writing new PLC programs for equipment, stations, or production lines from scratch.
Hands-on experience with Inductive Automation Ignition.
Experience developing Ignition screens, tags, scripting, and/or application architecture.
Experience integrating PLCs with MES or manufacturing information systems.
Understanding of manufacturing transactions such as work-order validation, traceability, recipes, production reporting, and serial-number tracking.
Experience commissioning automated manufacturing equipment.
Strong troubleshooting skills across controls hardware, PLC software, industrial networks, and production systems.
Experience in automotive or other high-volume discrete manufacturing environments.
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