Description
Controls Engineer
Location: Bengaluru
Department: Production
Experience: 04-06 Years
Job Purpose (Significance of the role & Objectives)
The Controls Engineer is responsible for developing, programming, and maintaining the control systems (PLCs, HMIs, SCADA) that drive automation equipment across the battery pack manufacturing line. This role ensures that all automated systems function efficiently, safely, and are fully integrated with MES for traceability and data collection.
Key Responsibilities and Deliverables
- Develop, test, and maintain PLC programs for various automation assembly stations (adhesive dispensing, assembly, conveyors).
- Configure HMIs for operator interfaces, alarm handling, and machine diagnostics
- Integrate robots, sensors, cameras, and actuators into unified control architecture.
- Support installation, FAT/SAT, and on-site commissioning of automated systems.
- Diagnose and resolve control issues, electrical faults, and software bugs quickly to minimize downtime.
- Establish communication protocols (OPC-UA, Modbus, Profinet, Ethernet/IP) for seamless device interaction.
- Configure data logging and ensure process traceability by linking PLC systems to MES/SCADA
- Work closely with IT/MES teams to implement data exchange and production reporting.
- Develop preventive maintenance programs for control systems
- Continuously improve PLC/HMI code for better performance and reliability
- Train technicians and operators on safe use of automated systems.
Desired Qualifications: Required Qualification, Knowledge, and Experience
- Bachelor’s degree in Electrical / Electronics / Instrumentation / Controls Engineering
- 2–6 years of hands-on experience in PLC/HMI programming, control panel design, and system commissioning in manufacturing or automation industries
- Strong in PLC programming (Siemens TIA Portal, Allen-Bradley Studio 5000, Mitsubhishi, Beckhoff TwinCAT).
- HMI/SCADA configuration (Open source software's, WinCC, FactoryTalk, Ignition, Wonderware).
- Knowledge of communication networks and industrial protocols
- Exposure to robotics and MES connectivity.
- Understanding of electrical safety, control panels, and instrumentation
- Analytical thinking, quick troubleshooting, teamwork, documentation discipline, and communication with cross-functional teams
Key Competencies
- Result oriented/Goal driven.
- Proficiency in oral and written communication.
- Self-motivated, passionate about learning, and takes initiative with a problem-solving attitude.
- Highest level of integrity (teamwork, confidentiality, ethics, and integrity are the pre-requisite for the role).
- Sense of ownership and pride in his/her performance and its impact on the company’s success.
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