Senior Controls Engineer

What we offer:

At Magna, you can expect an engaging and dynamic environment where you can help to develop industry-leading automotive technologies. We invest in our employees, providing them with the support and resources they need to succeed. As a member of our global team, you can expect exciting, varied responsibilities as well as a wide range of development prospects. Because we believe that your career path should be as unique as you are.

Group Summary:

Transforming mobility. Making automotive technology that is smarter, cleaner, safer and lighter. That’s what we’re passionate about at Magna Powertrain, and we do it by creating world-class powertrain systems. We are a premier supplier for the global automotive industry with full capabilities in design, development, testing and manufacturing of complex powertrain systems. Our name stands for quality, environmental consciousness, and safety. Innovation is what drives us and we drive innovation. Dream big and create the future of mobility at Magna Powertrain.

Job Responsibilities:

Scope of Position

• The Sr. Controls Engineer is responsible for designing, developing, and optimization of advanced automation and control systems while supervising all aspects of the plant electrical control systems, equipment, and machinery while guiding the non-senior controls engineers involved in a Tier 1 automotive manufacturing environment.
• This role will involve mentoring junior engineers, leading complex automation projects, and driving Industry 4.0 initiatives to enhance production efficiency, quality, and reliability.
• Responsible for the specification, installation and technical support of PLC-based hardware and software. The goal is to ensure that the plant is running smoothly and efficiently while also meeting quality and safety standards.
• Writes and improves control programs to support operations achieving required cycle times, improve equipment uptime (reduce down time) in a safe operations mode, develops suggestions for improvements, and prepares cost and timing information for projects. Works with internal and external resources to understand all requirements to ensure all project needs are met. Implements changes and improvement following the change management system. The scope of equipment includes Robots, Transfer systems, assembly equipment, laser cutting, vision / camera inspection, AMR / AGVs, automation, and other machinery and support structure.

Minimum Requirements

• Bachelor’s degree in Electrical Engineering, Automation, Mechatronics, or a related field.
• 5+ years of experience in a controls engineering role in a high-volume manufacturing environment, preferably in a Tier 1 supplier, automotive OEM, and / or integrator designing / building / commissioning automation equipment.
• Expert proficiency in PLC programming (Siemens, Allen Bradley), industrial robotics, and network protocols (Ethernet/IP, OPC UA).  Hands-on experience with MES, SCADA, IIoT, and Industry 4.0 technologies.
• Strong analytical skills, problem-solving mindset, and ability to manage multiple projects at the same time.
• Must be able to interpret and design electrical schematics.
• Mentoring and leadership experience, with a passion for developing junior engineers.
• Must be continuous improvement minded and must understand the “7 wastes” to write effective programs. Must have ability to multitask. Must be adaptable, striving to find creative solutions to problems as they arise.
• Flexible with completing job responsibilities.

Job Specific Responsibilities

Advanced Automation & Controls

• PLC & HMI Programming: Develop, optimize, and troubleshoot PLC (Siemens, Allen Bradley) and HMI systems for production lines.

• Robotics & Vision Systems: Integrate and program industrial robots (Fanuc, ABB, KUKA) and vision systems (Cognex, Keyence) for quality and process control.
• MES & SCADA Integration: Develop and enhance MES/SCADA systems to enable real-time production monitoring and data-driven decision-making.

Industry 4.0 & IIoT Implementation

• Smart Manufacturing: Deploy IIoT solutions, predictive maintenance systems, and digital twin technology to improve process efficiency.
• Big Data & Cybersecurity: Implement data analytics strategies while ensuring cybersecurity compliance within the industrial network.

Process Optimization & Error Proofing

• Develop and implement Poka-Yoke techniques, in-process inspections, and statistical process control (SPC) to drive zero-defect manufacturing.
• Conduct root cause analysis (5-Why, Fishbone) and lead problem-so