Production Scheduling Coordinator - Level II
Cummins · Dewas
Position Summary
The Controls Engineer (Electrical & Electronic Maintenance) & LOTO Leader is responsible for developing, maintaining, troubleshooting, and optimizing electrical, electronic, controls, and automation systems across manufacturing operations. The role provides technical expertise for PLCs, HMIs, industrial networks, drives, robotics, sensors, and automated equipment to support safe, reliable, and efficient manufacturing.
In addition, this role serves as the plant Lockout/Tagout (LOTO) Leader and Subject Matter Expert (SME), responsible for governing hazardous energy control programs, ensuring machine safety compliance, conducting audits and risk assessments, and promoting a proactive, zero-incident safety culture.
The role also provides technical leadership, coaches and mentors less experienced Controls Engineers and maintenance personnel, and drives continuous improvement across manufacturing processes and equipment.
Key Responsibilities
1. Electrical, Electronics & Controls Engineering
- Provide expert technical support and troubleshooting for PLCs, HMIs, industrial networks, servo/VFD drives, sensors, robotics, and automated manufacturing equipment.
- Diagnose complex electrical, electronic, and controls-related machine breakdowns and implement effective containment and permanent corrective actions.
- Develop, modify, and maintain control systems, machine programs, electrical schematics, software, calibration files, and program version revisions.
- Support the installation, commissioning, and technical support of PLC-based hardware and software.
- Develop and implement bench tests and modify software and equipment to ensure sensors, actuators, and control systems function according to specifications.
- Support and debug complex technical problems, engineering changes, and change requests.
- Partner with production, maintenance, engineering, and cross-functional teams to support automated machining, assembly, and testing operations.
2. Equipment Reliability & Manufacturing Automation
- Support Total Productive Maintenance (TPM), preventive maintenance, and predictive maintenance activities for electrical and control systems.
- Analyze downtime, MTBF, MTTR, and Pareto trends to identify recurring equipment and automation failures.
- Implement hardware, software, and logic modifications to improve Overall Equipment Effectiveness (OEE), cycle time, equipment availability, and reliability.
- Implement automation improvements using available technologies, programming techniques, and appropriate materials and resources.
- Develop and implement solutions to improve machine utilization and overall manufacturing performance.
- Support continuous improvement initiatives using Lean and Six Sigma methodologies.
3. LOTO & Hazardous Energy Control
- Serve as the plant Champion and Subject Matter Expert for Lockout/Tagout (LOTO) and hazardous energy control.
- Develop, review, update, and validate Machine-Specific Energy Control Procedures for new, modified, and existing manufacturing equipment.
- Lead hazardous energy risk assessments and safety reviews for equipment modifications, installations, commissioning, and maintenance activities.
- Conduct periodic LOTO inspections, field compliance audits, and competency evaluations for authorized and affected personnel.
- Conduct qualification and training programs for authorized LOTO employees and contractors.
- Promote proactive safety behaviors, risk identification, reporting, and compliance with EHS standards.
4. Machine Safety, Audits & Incident Investigation
- Verify and maintain machine safety systems including safety PLCs, interlocks, light curtains, emergency stops, and guarding systems.
- Identify electrical, hydraulic, pneumatic, and controls-related hazards and ensure appropriate safe work practices are incorporated into daily activities.
- Lead or participate in electrical and machine safety incident and near-miss investigations using structured root cause analysis methodologies such as 5 Whys, Fishbone/Ishikawa, and other RCA tools.
- Participate in internal, external, ISO 45001, and ISO 14001 audits and support compliance with applicable electrical, machine safety, and corporate HSE requirements.
- Champion a safe and injury-free manufacturing environment through proactive identification and mitigation of hazards.
5. Controls Engineering, Projects & Governance
- Develop and design control systems and support new equipment installations, upgrades, and manufacturing projects.
- Specify, review, and approve company-owned or supplier-provided controls designs for new equipment and upgrades to existing equipment.
- Investigate project requirements and develop technical solutions considering cost, resources, personnel, safety, and environmental requirements.
- Prepare cost estimates and compile equipment and technical information required for appropriation requests.
- Support controls system security by reviewing and implementing appropriate security requirements for manufacturing controls and systems.
- Manage critical electrical and automation spare parts to minimize equipment downtime and operational risks.
6. Training, Coaching & Collaboration
- Develop and deliver technical training for maintenance and engineering teams on electrical troubleshooting, controls systems, schematic interpretation, and safe diagnostic practices.
- Coach and mentor less experienced Controls Engineers and technical personnel.
- Build effective partnerships with production, maintenance, engineering, EHS, suppliers, and other cross-functional teams.
- Communicate technical information effectively to different audiences and maintain technical continuity across shifts.
- Promote collaboration, inclusion, and the value of diverse perspectives within the organization.