Sr. Engineer, Controls & Automation

Sr. Engineer, Controls & Automation

Work Mode: Onsite

Location:  Onsite - Casa Grande, AZ

Opportunity

The Senior Controls & Automation Engineer is responsible for supporting, maintaining, and improving automation systems to achieve safety, quality, delivery, and cost objectives within a highly automated manufacturing environment. This role focuses on controls system reliability, robotics, automation projects, troubleshooting, continuous improvement, and the implementation of new technologies.

The primary area of responsibility supports molding operations, including a fleet of FANUC industrial robots, PLC-based machine controls, HMI/SCADA systems, and automated production equipment. The ideal candidate combines strong automation and controls expertise with a hands-on mechanical engineering background and the ability to design, troubleshoot, and improve automated manufacturing systems.
This position works closely with Production, Maintenance, Quality, Process Engineering, and Operations to improve equipment performance, increase manufacturing efficiency, and support plant growth.

What We Offer
• Competitive salary with annual merit increases and bonus potential
• Wide array of benefits, including medical, dental, vision, wellness incentives, and maternity/parental leave
• 401k savings plan
• Company-funded pension plan with vesting after 5 years of service
• Career advancement opportunities, tuition reimbursement, and employee discounts
• Company-paid relocation package

Responsibilities

• Support daily manufacturing operations and resolve controls, robotics, and automation-related issues.
• Lead troubleshooting efforts for PLCs, HMIs, robotics, machine vision systems, industrial networks, and automated equipment.
• Develop, maintain, and improve Rockwell Automation control systems, including ControlLogix and CompactLogix platforms.
• Configure, develop, and support Ignition HMI/SCADA applications.
• Support and optimize a manufacturing environment consisting of 90+ FANUC industrial robots.
• Lead root cause analysis and corrective actions for equipment downtime, automation failures, and process-related concerns.
• Identify and implement automation and continuous improvement projects.
• Develop and maintain controls standards, documentation, electrical drawings, and programming standards.
• Support capital projects involving automation equipment, robotics, controls upgrades, and new production lines.
• Collaborate with Process Engineering, Production, and Maintenance teams to improve equipment performance.
• Support machine commissioning, startup, validation, and operator training activities.
• Promote and support safe machine design, safeguarding, and automation safety initiatives.

Skills/Requirements

• Bachelor’s degree in Mechanical Engineering, Mechatronics Engineering, Electrical Engineering, Automation Engineering, or related engineering discipline from an ABET-accredited program.
• 3+ years of experience in controls engineering, automation engineering, manufacturing engineering, or a related role.
• Experience with Rockwell Automation Logix5000 platforms.
• Experience supporting industrial robotics, preferably FANUC systems.
• Experience with HMI/SCADA development and support; Ignition experience preferred.
• Strong troubleshooting and root cause analysis skills in a manufacturing environment.
• Knowledge of industrial networking protocols such as EtherNet/IP, OPC UA, IOLink, BACNet, and Modbus TCP.
• Strong mechanical aptitude and understanding of machine design, tooling, pneumatics, motion systems, and automated equipment.
• Experience with 3D modeling software such as SolidWorks, Inventor, Creo, or similar CAD platforms.
• Experience with 3D printing, fixture design, and rapid prototyping is a plus.
• Experience with machine vision systems is preferred.
• Experience with Beckhoff controls is a plus.
• Experience with machine safety systems, risk assessments, and safety PLCs is a plus.
• Experience in a high-volume automated manufacturing environment is preferred.
• Authorized to work in the United States without employer sponsorship now or in the future.

Applicants must be authorized to work in the US without requiring sponsorship now or in the future.

We believe in supporting you from the moment you join us, which is why Kohler offers day 1 benefits. This means you’ll have access to your applicable benefit programs from your first day on the job, with no waiting period. The salary range for this position is $92,400 - $141,000. The specific salary offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location. In addition, this position is eligible for a performance bonus/variable incentive compensation.

Why Choose Kohler?
We empower each associate to #BecomeMoreAtKohler with a competitive total rewards package to support your health and wellbeing, access to career growth and development opportunities, a diverse and inclusive workplace, and a strong culture of innovation. With more than 30,000 bold leaders across the globe, we’re driving meaningful change in our mission to help people live gracious, healthy, and sustainable lives.

About Us
It is Kohler’s policy to recruit, hire, and promote qualified applicants without regard to race, creed, religion, age, sex, sexual orientation, gender identity or expression, marital status, national origin, disability or status as a protected veteran. If, as an individual with a disability, you need reasonable accommodation during the recruitment process, please contact kohlerjobs@kohler.com. Kohler Co. is an equal opportunity/affirmative action employer.