Controls Engineer - Senior at CUMMINGS INC

Phaltan, maharashtra, India -

Full Time

Start Date

Immediate

Expiry Date

20 Sep, 26

Salary

0.0

Posted On

22 Jun, 26

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Siemens S7-1500 PLC, Robotics Programming, HMI/SCADA Development, Industrial Networking, Servo Drives & VFDs, Ladder Logic, Function Block Diagram, Structured Control Language, Machine Safety Systems, Root Cause Analysis, Project Planning, Industry 4.0, ABB Robotics, FANUC Robotics, Yaskawa Robotics, Control System Integration

Industry

Motor Vehicle Manufacturing

Description

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. Cummins is an equal opportunity employer. Our policy is to provide equal employment opportunities to all qualified persons without regard to race, sex, color, disability, national origin, age, religion, union affiliation, sexual orientation, veteran status, citizenship, gender identity, or other status protected by law.

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Responsibilities

Develops and supports automation and control systems for manufacturing equipment, focusing on PLC programming and robotics integration. Responsible for commissioning, process optimization, and ensuring compliance with safety and quality standards.