Controls Engineer

Job Purpose Engineer – ME Controls is responsible for designing, developing, & implementing advanced automation & control systems for Dana TM4’s EV powertrain manufacturing lines. The role involves SCADA architecture, MES integration (IoT 4.0), PLC programming, PCB design & failure analysis, & high-voltage/low-voltage motor assembly line controls. The position ensures robust, scalable, & compliant control solutions for inverter & motor production, driving Industry 4.0 readiness, process optimization, & zero-defect manufacturing. Job Duties and Responsibilities

SCADA Development: Design & deploy SCADA systems for real-time process monitoring, alarms, & data acquisition.

MES & IoT 4.0: Implement MES solutions integrated with IoT sensors for predictive maintenance & digital twin applications.

PLC Programming: Develop ladder logic & structured text programs for Siemens, Allen-Bradley, & Beckhoff PLCs; ensure fail-safe operations.

PCB Design & Testing: Create PCB layouts for control circuits, perform functional testing, & conduct root cause analysis for failures.

High-Voltage Safety: Design interlocks & safety circuits for HV motor assembly lines; ensure compliance with IEC & Dana standards.

Automation Projects: Lead end-of-line automation projects, including robotic integration & vision systems for quality assurance.

Data Analytics: Utilize Python/MATLAB for process data analysis & KPI dashboards for OEE improvement.

Cross-Functional Collaboration: Work with design, quality, & production teams to support EV inverter & motor NPD (New Product Development).

Education and Qualifications

Diploma/Degree in Electrical/Electronics/E&TC Engineering.

Hands-on experience in automation & controls engineering for EV manufacturing.

Proficiency in PLC, SCADA, MES, & IoT integration.

Knowledge of embedded systems & wiring harness programs.

Strong analytical, troubleshooting, & documentation skills.

Skills and Competencies

• Advanced SCADA & MES Architecture

• PLC Programming (Siemens TIA Portal, Allen-Bradley RSLogix)

• PCB Design & Failure Mode Analysis

• High-Voltage Motor Assembly Line Controls

• Embedded Systems & Arduino Prototyping

• IPC Wiring Harness Standards

• Data Analytics & Predictive Maintenance

• Industry 4.0 Implementation & Digital Manufacturing