Controls Engineer – High-Pressure Die Casting (HPDC)

We’re ALTEN Technology USA, an engineering company that provides solutions for engineering, technology, and product development projects. For decades, we’ve been helping our clients develop products that are changing the world, whether that’s by shaping the future of space exploration, saving lives with medical devices that set a new standard of care, or creating the fully autonomous electric taxi of tomorrow. Our team of more than 600 people works across industries including aerospace, medical devices and life sciences, unmanned systems and robotics, automotive OEM and tier 1 suppliers, commercial vehicle, electric vehicles, rail, and more. Our offices across the US have different industry focuses and engage with our clients in different ways, ranging from working on-site at client facilities to performing product development at our delivery centers.
 
ALTEN Group, our parent company, has been a leader in engineering and information technology for more than 30 years. ALTEN Group operates in 30 countries across Europe, North America, Asia, Africa and the Middle East and employs more than 36,000 people, 88% of whom are engineers. The company covers the whole development cycle and offers a choice of service levels, from technology consulting to complete project outsourcing.
 
When you join ALTEN Technology USA, you join a group of people passionate about collaborating to solve some of the world’s most technical engineering challenges. Our success is tied to taking care of our employees by building relationships and providing opportunities for mentorship and career growth. We offer comprehensive benefits for all full-time employees, including medical, dental, and vision insurance; a 401(k) plan with employer matching; paid time off (PTO); paid parental leave; and mentorship to help you take your career to the next level. You don’t have to take our word for it that we are a great place to work—we were named on the 2023 Top Workplaces list thanks to feedback from our proud employees.

Job Description :

The Controls Engineer – HPDC is responsible for the design, programming, troubleshooting, and optimization of control systems for high-pressure die casting (HPDC) equipment in the automotive industry. This role involves Allen-Bradley PLC programming, HMI development, and automation system integration to ensure efficient, high-quality production processes. The engineer will work closely with cross-functional teams to improve machine performance, minimize downtime, and support new vehicle model launches.

Key Responsibilities:

• Develop, program, and troubleshoot control systems for HPDC equipment, focusing on Allen-Bradley PLCs (Rockwell Automation).
• Design and optimize HMI and SCADA systems to improve operator interface and process monitoring.
• Diagnose and resolve automation and electrical control system issues, ensuring maximum overall equipment effectiveness (OEE).
• Configure and maintain industrial communication networks (EtherNet/IP, ControlNet, DeviceNet).
• Collaborate with manufacturing, maintenance, and engineering teams to support new model launches and production capacity expansions.
• Integrate and optimize robotics, servo systems, and motion control applications in HPDC operations.
• Develop and implement predictive maintenance and fault detection strategies to minimize downtime.
• Ensure compliance with automotive industry standards (IATF 16949, PPAP, APQP, and GD&T).
• Lead continuous improvement initiatives to enhance automation efficiency, cycle time reduction, and defect elimination.
• Maintain and update electrical schematics, PLC programming documentation, and troubleshooting guides.
• Support commissioning, validation, and integration of new HPDC automation systems.

Qualifications:

• Bachelor’s degree in Electrical Engineering, Automation Engineering, or related field.
• 5+ years of experience in control systems for HPDC or automotive manufacturing.
• Strong expertise in Allen-Bradley PLC programming, troubleshooting, and system integration.
• Experience with HMI design, SCADA systems, and industrial robotics in manufacturing environments.
• Knowledge of die casting automation, servo systems, and motion control technologies.
• Familiarity with i