Project Engineer - Controls & Robotics

Long Description

Orise (PA Solutions, an ATS Company) delivers complex, turnkey automation systems for global OEMs and Tier-1s in automotive, aerospace, and advanced manufacturing. Our controls and robotics teams design, program, integrate, and commission highly sophisticated production systems used worldwide.

The Project Engineer – Controls & Robotics; owns the controls, automation, and integration deliverables for assigned machine or system areas. This role is responsible for PLC/HMI programming, robot programming, troubleshooting, commissioning, and supporting successful FAT/SAT and production launch. You will work closely with mechanical, software, and project management teams to deliver safe, reliable, technically robust automation systems. In addition, you will oversee and coordinate third-party suppliers responsible for long-lead equipment, ensuring alignment to technical requirements, quality expectations, and project timelines. The Project Engineer also supports project management in all change-management proceedings, helping evaluate, document, and implement engineering changes as the project evolves.

Overall, this role is both a technical design owner and a cross-functional integrator, ensuring smooth communication and alignment between engineering, manufacturing, project management, and external suppliers to deliver high-quality automation systems.

Key Responsibilities:
Controls & Robotics Execution
 Oversee development and implement PLC programs (Siemens TIA Portal, Rockwell Studio 5000, etc.) including HMI screens, alarms, diagnostics, and safety logic.
 Oversee program and integrate industrial robots (Fanuc, ABB, KUKA) including EOAT configuration, frames, paths, routines, payloads, and fault recovery sequences.
 Oversee configuration and diagnose industrial networks (Ethernet/IP, Profinet, OPC-UA, IO-Link).
 Support electrical design reviews (control architecture, IO counts, panel layouts, device selection).
 Validate IO, tune motion, perform device bring-up, and troubleshoot servo, vision, sensor, and safety hardware.
Project & System Coordination
 Participate in system design reviews, PFMEAs, functional specifications, and sequence of operations creation.
 Breakdown controls tasks and provide hour estimates, assumptions, and risk identification.
 Support project managers with technical content for customer meetings, timelines, and issue logs.
 Identify scope gaps, flag change order opportunities, and ensure alignment with customer standards.
FAT/SAT & Commissioning
 Lead bench test, debug, and commissioning activities for your assigned zones or stations.
 Support run-offs, cycle-time optimization, OEE improvement, and line readiness.
 Carry out site acceptance testing (SAT), troubleshooting, and launch support at customer site.
 Document punch lists and ensure timely closure.
Documentation & Standards
 Maintain controls deliverables (IO lists, device sheets, code standards, HMI templates).
 Contribute to continuous improvement of standard code objects, diagnostic structures, and integration methods.

Additional Information

Qualifications (must have)

 Bachelor’s degree in Electrical Engineering, Mechatronics, Computer Engineering, or equivalent experience.
 3–5 years of PLC/HMI programming experience in a machine-build or automation project environment.
 Automotive or aerospace automation experience.
 Hands-on robot programming experience (Fanuc, ABB, or KUKA).
 Ability to read and interpret electrical schematics, device datasheets, and safety circuits.
 Experience with industrial networks, remote IO, VFDs, sensors, and servo systems.
 Strong debugging and problem-solving background during build/commissioning.
 Experience with vision systems (Cognex, Keyence) or advanced motion control.

Travel & Work Environment

 Travel 10–40%, depending on commissioning phase and customer location.
 Hybrid work possible during engineering phases.