Controls Engineer
Pune, MH, IN, 410501
Requisition:
63339
Job Purpose
Engineer – ME Controls is responsible for designing, developing, & implementing advanced automation & control systems for Dana TM4’s EV powertrain manufacturing lines. The role involves SCADA architecture, MES integration (IoT 4.0), PLC programming, PCB design & failure analysis, & high-voltage/low-voltage motor assembly line controls. The position ensures robust, scalable, & compliant control solutions for inverter & motor production, driving Industry 4.0 readiness, process optimization, & zero-defect manufacturing.
Job Duties and Responsibilities
- SCADA Development: Design & deploy SCADA systems for real-time process monitoring, alarms, & data acquisition.
- MES & IoT 4.0: Implement MES solutions integrated with IoT sensors for predictive maintenance & digital twin applications.
- PLC Programming: Develop ladder logic & structured text programs for Siemens, Allen-Bradley, & Beckhoff PLCs; ensure fail-safe operations.
- PCB Design & Testing: Create PCB layouts for control circuits, perform functional testing, & conduct root cause analysis for failures.
- High-Voltage Safety: Design interlocks & safety circuits for HV motor assembly lines; ensure compliance with IEC & Dana standards.
- Automation Projects: Lead end-of-line automation projects, including robotic integration & vision systems for quality assurance.
- Data Analytics: Utilize Python/MATLAB for process data analysis & KPI dashboards for OEE improvement.
- Cross-Functional Collaboration: Work with design, quality, & production teams to support EV inverter & motor NPD (New Product Development).
Education and Qualifications
- Diploma/Degree in Electrical/Electronics/E&TC Engineering.
- Hands-on experience in automation & controls engineering for EV manufacturing.
- Proficiency in PLC, SCADA, MES, & IoT integration.
- Knowledge of embedded systems & wiring harness programs.
- Strong analytical, troubleshooting, & documentation skills.
Skills and Competencies
- Advanced SCADA & MES Architecture
- PLC Programming (Siemens TIA Portal, Allen-Bradley RSLogix)
- PCB Design & Failure Mode Analysis
- High-Voltage Motor Assembly Line Controls
- Embedded Systems & Arduino Prototyping
- IPC Wiring Harness Standards
- Data Analytics & Predictive Maintenance
- Industry 4.0 Implementation & Digital Manufacturing