Senior Controls Engineer

As AESC ramps up new battery manufacturing facilities across the Southeastern United States to meet rising demand from automotive OEM partners, we are expanding our local engineering teams to support smooth plant launches.

As Senior Control Engineer (Production Equipment Development) working with the Global Industrial Development team, you will provide controls engineering solutions to seamlessly integrate production equipment controls with the overall facility control system. Using your expertise in production equipment control design and development, you will collaborate with cross-functional design teams to create control system and data architectures that unify all plant operations. Your objective is to tie together equipment, processes, and logistics controls to optimize efficiency, throughput, and automation for the facility complete system.

Core responsibilities include:

• Ensuring robust integration between equipment controls and the site MES/SCADA system
• Working with Facility design team to ensure equipment and facility controls systems are compatible and optimized.
• Partnering with production equipment engineering teams to define equipment control requirements and data needs
• Design and develop PLC/HMI control systems, motion control, robotics, and sensors to automate battery manufacturing processes including material handling, assembly, testing, and packaging
• Select and integrate various automation components including PLCs, HMIs, drives, motors, sensors, vision systems, robotics, conveyors, and safety devices
• Designing machine control panels, I/O networks, and PLC/HMI logic for new manufacturing platforms
• Developing standards, templates, and architectures to streamline controls implementation across the site
• Program PLCs, PACs, SCADA systems using ladder logic, structured text, and function block programming
• Providing guidance to contractors/integrators on control system testing, validation, and launch protocols
• Identifying and spearheading adoption of new control technologies to increase quality and automation
• Leading troubleshooting and continuous improvement initiatives to boost equipment effectiveness
• Maintaining expert-level knowledge of leading control platforms and international standards compliance
• Reporting to the Project Director, you will ensure our local launch team provides critical design inputs
• technicians and engineers while managing deliverables across the site development lifecycle.

Technical Skills:

• In-depth knowledge of battery manufacturing processes, equipment, and technologies
• Engineering expertise relevant to the position such as mechanical, electrical, chemical, industrial, or automation
• Understanding of lean manufacturing principles and continuous improvement methodologies
• Experience with commissioning, validating, and optimizing production equipment and processes
• Strong analytical and problem-solving abilities
• Proficiency using data analytics and manufacturing software/tools
• Extensive experience with equipment development and factory acceptance testing (FAT)

Leadership Skills:

• Ability to lead and influence cross-functional & cross-cultural technical teams
• Excellent team building, motivation, and coaching skills
• Strong project management, planning, and organizational abilities
• Decisive leadership style with a bias for action
• Skilled at stakeholder engagement and change management

Other Requirements:

• BS degree in Electrical, Controls, Mechatronics Engineering or related field
• 5+ years experience programming PLCs and HMIs for process automation and machine control
• Hands-on experience with major PLC/HMI platforms such as Siemens, Rockwell Automation, Schneider Electric, Omron, Ignition,
• Proficiency in development environments such as Siemens Step 7, Studio 5000, Vijeo Designer
• Experience with Ethernet network layout and design for supporting facilities and manufacturing equipment communication and control.
• Experience with industrial networking protocols including EtherNet/IP, Modbus, Profinet
• Understanding of instrumentation and experience integrating sensors, vision systems, etc.
• Knowledge of motion control techniques and robotics integration
• Excellent troubleshooting and analytical skills
• Strong communication and documentation abilities

The ideal candidate will combine in-depth technical expertise with seasoned leadership abilities to manage complex equipment launches and drive manufacturing performance.

Base Location: Southeast US (TN, KY, SC), remote hybrid

Travel: up to 30% within region (US) and foreign (UK, EU, CH JP, others) travel for project support.

What we offer:

Welcome to our state-of-the-art Gigafactory, where you'll have the opportunity to tackle the world's most fascinating challenges alongside exceptionally talented individuals who are driven to make a difference. At AESC, we offer a comprehensive compensation package, including a competitive salary and a rewarding AESC bonuses program. In addition, we provide a range of valuable benefits, such as 401K, health insurance, and relocation and commuting support. We strive to ensure that our employees are well taken care of, enabling them to focus on their work and contribute to our collective mission of changing the world.

PHYSICAL REQUIREMENTS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable otherwise qualified individuals with disabilities to perform the essential job functions.

• Ability to sit for extended periods of time.
• Ability to read, write, speak, hear; stand; walk; use hands to finger, handle, or feel; reach and lift with hands and arms frequently throughout the day.
• Required to occasionally lift, push, pull and/or move up to 10 pounds and occasionally required to lift, push, pull and/or move up to 35 pounds.

WORK ENVIRONMENT

The work environment is primarily an automated manufacturing plant with a concrete floor and is characterized by some temperature extremes, moderate noise, and forklift traffic. The individual must be able to perform all essential functions as appropriate on the plant floor, in meetings, and with employees, management, customers and suppliers.

Candidate must perform the essential duties and responsibilities with or without reasonable accommodation efficiently and accurately, and without causing significant safety threat to self or others. The statements made herein are intended to describe the general nature and level of work being performed by employees assigned to this job classification. They are not intended to be construed as an exhaustive and inclusive list of all responsibilities, duties, and/or skills required of personnel so classified.

Equal Opportunity Employer

All of us at AESC – regardless of functional area or expertise – share a passion to design, manufacture, and sell high-performance products. It is our policy to provide Equal Employment Opportunity (EEO) to all persons regardless of race, gender, disability, or any other status protected by law. Candidates for this position must be legally authorized to work in the United States and will be required to provide proof of employment eligibility at the time of hire.

"We participate in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S."