Job Summary

Develops, designs, implements, and supports automation and control systems for manufacturing equipment, machines, and production lines. Responsible for PLC programming, robotics integration, control system development, troubleshooting, commissioning, process optimization, and continuous improvement initiatives. Ensures reliable operation of automation systems while maintaining compliance with safety, quality, and operational standards.

Key Responsibilities

Develop, modify, troubleshoot, and optimize PLC programs, robot logic, and automation control systems.
Design end-to-end automation solutions for manufacturing equipment and production lines, including control philosophy, sequence logic, and safety architecture.
Program and support Siemens S7-1500 PLCs and industrial automation systems.
Configure, program, and troubleshoot ABB, FANUC, and Yaskawa robotic systems.
Develop reusable software modules, function blocks, and standardized control architectures.
Integrate robots, vision systems, conveyors, manipulators, servo drives, VFDs, safety PLCs, and other automation devices.
Configure and maintain industrial communication networks including Profinet, Ethernet/IP, Modbus, and OPC UA.
Design and improve HMI and SCADA systems, including dashboards, alarm management, data logging, and trend analysis.
Support Industry 4.0 initiatives, predictive maintenance programs, and digital manufacturing solutions.
Lead equipment installation, commissioning, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and production ramp-up activities.
Perform root cause analysis using structured problem-solving methodologies such as 5 Why, Fishbone Analysis, Fault Tree Analysis (FTA), and implement permanent corrective actions.
Conduct breakdown analysis and resolve complex automation, electrical, and controls-related issues to minimize downtime.
Develop and execute preventive and predictive maintenance plans for automation equipment.
Monitor and improve Overall Equipment Effectiveness (OEE), cycle time, throughput, reliability, and process efficiency.
Validate and maintain machine safety systems, including LOTO procedures, interlocks, emergency circuits, guarding systems, and safety PLCs.
Prepare technical documentation, project plans, equipment specifications, cost estimates, and engineering reports.
Collaborate with production, quality, maintenance, suppliers, OEMs, and cross-functional teams to support manufacturing objectives.
Coach, mentor, and provide technical guidance to junior engineers and technicians.
Ensure compliance with Cummins Health, Safety, Environmental (HSE), quality, and manufacturing standards.

Qualifications

Required

Bachelor's Degree in Engineering, Automation, Electrical Engineering, Electronics Engineering, Mechatronics, STEM-related field, or equivalent experience.
Intermediate level of relevant automation, controls engineering, or manufacturing experience.

Preferred

Experience in automotive, manufacturing, industrial automation, or robotics environments.
Certifications or specialized training in PLC programming, robotics, SCADA, or industrial automation.

Competencies

Collaborates
Communicates Effectively
Customer Focus
Drives Results
Decision Quality
Health and Safety Fundamentals
Controls Engineering Knowledge
Controls Networking
Controls Safety
Controls System Security
Electrical System Troubleshooting
Factory Automation and Control Systems
Machine Programming
Manufacturing Knowledge
Sensor Technology and Measurement
Self-Development
Values Differences

Skills

Technical Skills

Siemens S7-1500 PLC programming and troubleshooting.
Robotics programming, teaching, commissioning, and troubleshooting (ABB, FANUC, Yaskawa).
HMI and SCADA development and support.
Automation and control system integration.
Industrial networking technologies including Profinet, Ethernet/IP, Modbus, and OPC UA.
Servo drives, VFDs, sensors, actuators, motion control, and control system hardware.
PLC programming languages including Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Control Language (SCL).
Advanced troubleshooting of electrical and automation systems.
Machine safety systems, Safety PLCs, LOTO, and industrial safety standards.
Controls system cybersecurity and network architecture.
Manufacturing process automation and continuous improvement methodologies.

Professional Skills

Root Cause Analysis (RCA), Fault Tree Analysis (FTA), and structured problem-solving techniques.
Strong analytical and decision-making abilities.
Effective communication and stakeholder management skills.
Collaboration and cross-functional teamwork.
Project planning, execution, and coordination.
Continuous improvement mindset and results orientation.
Coaching, mentoring, and technical leadership capabilities.

Experience

Intermediate level experience in controls engineering, factory automation, robotics, manufacturing systems, or related disciplines.
Hands-on experience with PLC programming, industrial automation systems, and robotics integration.
Experience supporting manufacturing equipment, production lines, and automation projects.
Proven experience in troubleshooting complex automation and electrical control systems.
Experience with commissioning, validation, process optimization, and continuous improvement initiatives is preferred.
Exposure to Industry 4.0 technologies, predictive maintenance, and smart manufacturing solutions is advantageous.

Job Manufacturing

Organization Cummins Inc.

Role Category On-site with Flexibility

Job Type Exempt - Experienced

ReqID 2430567

Relocation Package No

100% On-Site Yes

Due to the operational nature and specific job duties of this role, work is required to be completed 100% in person/On-site.

Controls Engineer - Senior