Maintenance Controls Engineer
Role Overview
Harbinger Motors is expanding, and we are looking for a Maintenance Control Engineer to support our advanced EV manufacturing lines (Battery, GA, EDU, Stator/Hairpin). This role bridges automation, controls, SCADA, and MES integration to ensure high equipment reliability, data accuracy, and maximum operational uptime. You will work hand-in-hand with Equipment Engineers, Manufacturing Engineers (MEs), Production, and external suppliers (both local and international) to resolve complex failures, implement continuous improvement initiatives, and execute seamless equipment transfers and upgrades.
What You'll Do:
Automation, Controls & MES Integration
Troubleshoot, program, and maintain PLCs (Siemens TIA Portal, Allen-Bradley Studio 5000), HMIs, and safety controllers.
Develop, configure, and maintain Ignition SCADA screens, tag structures, alarm pipelines, and system interfaces.
Support and troubleshoot data integration between machine controls and the Manufacturing Execution System (MES).
Diagnose and resolve issues on industrial networks (EtherNet/IP, Profinet, OPC-UA, Modbus, CAN).
Interpret, modify, and update electrical schematics, control loop diagrams, and P&IDs.
Vendor Support, Projects & Equipment Transfers
Collaborate directly with local and European equipment vendors/OEMs to troubleshoot complex controls issues, manage major repairs, and coordinate field service interventions.
Maintain a flexible schedule to overlap with European time zones and support critical project calls, factory acceptance testing (FAT/SAT), and remote support.
Work closely with Equipment Engineers and Manufacturing Engineers (MEs) on line installations, equipment transfers, commissioning, and engineering changes (ECR/ECN).
Continuous Improvement & Maintenance Engineering
Lead continuous improvement projects aimed at cycle-time reduction, automation optimization, line balancing, and overall downtime minimization.
Perform root-cause analysis (RCA, 5 Whys, 8D) on repeat control failures and implement robust corrective actions.
Establish and refine predictive and preventive maintenance protocols targeting machine availability (MTBF, MTTR, OEE).
Document all control updates and hardware modifications according to quality standards (ISO 9001, IATF 16949).
Safety & Operational Support
Provide direct technical support during line stoppages and production ramp-ups.
Train and mentor maintenance technicians on PLC diagnostics, Ignition SCADA troubleshooting, and safety system recovery.
Ensure all machine control modifications comply with OSHA, NFPA 70E, and machine safety standards (ISO 13849, EN/ISO 12100).
Who You Are:
Education:
Bachelor’s degree in Mechatronics, Electrical Engineering, Automation/Controls Engineering, Computer Engineering, or a related field.
Experience:
3–5 years of experience in controls, automation, or maintenance engineering within automated manufacturing.
Hands-on experience configuring and maintaining Ignition SCADA (Inductive Automation).
Direct experience integrating industrial machinery with MES platforms.
Proven history of working side-by-side with Manufacturing Engineers and Equipment Engineers on launch, transfer, or repair projects.
Technical Skills:
PLCs: Siemens TIA Portal (S7-1200/1500) and Allen-Bradley (ControlLogix, CompactLogix).
Software & Data: Ignition SCADA, MES architecture, basic SQL queries, and OPC-UA.
Hardware: 480VAC distribution, 24VDC controls, servo drives, vision systems (Keyence, Cognex), and sensors.
Ability to read technical manuals, schematics, and vendor documentation in English.
Work Flexibility & Soft Skills:
Flexibility to adapt work hours/shifts for communication and troubleshooting with European and local OEMs.
Strong cross-functional collaboration skills and a continuous-improvement mindset.
High analytical capability to perform fast, structured troubleshooting under pressure.
Preferred Qualifications
Ignition Core or Gold Certification.
Siemens or Rockwell automation technical certifications.
Experience with industrial robotics (Fanuc, ABB, KUKA).
Background in EV assembly, battery manufacturing, or high-volume automotive environments.
Six Sigma Green Belt certification.
Key Benefits & Perks:
Comprehensive Health, Dental & Vision (HDV) – 100% employee covered
Early-stage Stock Options
Robust Retirement Savings (401k, HSA, FSA)
Generous Paid Time Off (PTO) & Parental Leave
Annual Vacation Bonus
Wellness & Fertility Benefits
Cell Phone Stipend
Complimentary Meals & Stocked Kitchens
California Pay Range
$110,000—$180,000 USD