Senior Controls Engineer R&D

As a Controls Engineer in our Innovation Center, you will be responsible for designing, implementing, commissioning and maintaining automated systems to improve efficiency, reliability, and productivity in industrial processes. You will work closely with cross-functional local and remote teams to analyse requirements, develop automation solutions, integrate hardware and software components, and ensure seamless operation of automated systems.

 

Essential Functions/Duties:

Engineering Design & Development

• Apply sound engineering principles to design and develop advanced magnet wire production equipment, processes and programs to improve quality, efficiency, and cost.
• Perform hands-on design and implementation of machine and process automation, including electrical design, PLC programming and SCADA development.
• Design automation systems and develop detailed electrical schematics, BOMs and other technical documentation based on specifications, regulations, observations, budgets and project requirements.
• Develop and integrate new automation technologies to enhance performance of existing products and processes.
• Support and improve machine vision–based inspection systems (e.g., Keyence, Cognex).
• Interface with global Innovation Teams to share knowledge, provide technical expertise, and co-develop new equipment solutions.
• Contribute to development of intellectual property through innovative equipment and process design.
• Design and implement industrial networking architectures (Ethernet/IP, EtherCat, Modbus TCP, etc.) to ensure reliable, scalable, and high-performance communication between automation systems.
• Collaborate with IT and OT teams to develop secure, robust network infrastructures that support data acquisition, system integration, OPC, and enterprise connectivity while adhering to cybersecurity best practices.
• Ensure proper network segmentation, device configuration, and secure connectivity for industrial control systems to enable safe and resilient operations.
• Collaborate with mechanical, process and electronics engineering to ensure effective electro-mechanical system design and operation.
• Understand and apply basic mechanical concepts; fabricate or assemble basic components as needed to support controls systems.
• Continuously evaluate, adopt, and implement emerging controls technologies, including advanced automation, data analytics, machine learning, and AI-driven solutions to improve system performance and capability.
• Demonstrate a self-driven mindset with a strong desire for continuous learning, proactively seeking new technologies, tools, and methodologies while taking on challenging assignments to expand technical expertise.

System Deployment & Commissioning

• Provide technical support for equipment evaluation, installation, startup, commissioning, and product launch activities.
• Integrate automation systems with existing equipment and infrastructure, ensuring compatibility and seamless communication.
• Connect and configure equipment within SCADA systems (e.g., Ignition) for monitoring, visualization, and data collection, including SQL transactions.
• Conduct system testing, validation, and commissioning to ensure performance, reliability, and compliance with design requirements.
• Evaluate prototype equipment, document performance results, and recommend design improvements.
• Troubleshoot automation systems, diagnose issues, and implement corrective actions to minimize downtime and optimize system performance.

Project Management & Documentation

• Assist with project planning, scope definition, project management and execution in coordination with cross-functional teams.
• Utilize project planning software such as Monday.com or MS Project
• Communicate project milestones, risks, timelines, and critical paths to ensure on-time & on-budget delivery.
• Develop and maintain comprehensive technical documentation, including:

• Functional specifications
• Wiring diagrams
• Configuration files
• Operating procedures

• Maintain accurate records of system changes, revisions, and technical updates.

Support proc