4 Controls Engineers: Ford KCAP Tire Line

Four controls engineers are needed on a new automated tire assembly line at Ford’s Kansas City Assembly Plant (KCAP), and the number itself is the story. Not one specialist for a week — four engineers, starting as soon as they are free and running through the end of the year. The work is to install and commission a new automated line on Allen-Bradley PLCs and HMIs, Fanuc robots, and Keyence 3D vision, at $76 per hour plus travel. Here is why a build like this takes a crew, and why it takes the rest of the year.

A New Line Is Three Builds at Once

A finished line looks like one machine. It is built like three. The Allen-Bradley side is the nervous system — the PLC logic in Studio 5000, the FactoryTalk HMIs, the interlocks and sequencing that decide what moves and when. The Fanuc side is the muscle — robots picking, placing, seating and marrying parts, each one taught and tuned to its station. The Keyence side is the conscience — 3D laser vision measuring that every part is present, seated and in spec before the line lets it pass. Those three stacks have to come up together, talk to each other, and agree at production speed. Stretch one engineer across all of it and the line comes up in series, slowly. Put a crew on it and the disciplines come up in parallel — which is exactly what a launch date demands.

Why Four, and Not One

Four is not padding; it is how a line hits a date. With a crew, the PLC logic and the robot stations and the vision checks get built at the same time instead of one after another, and when two of them disagree on the floor — the robot says the part is placed, the vision says it is a millimeter proud — there are enough hands to chase the cause without stopping everything else. Commissioning a new line is long stretches of methodical work punctuated by problems that need to be solved now. A team can hold both: steady progress on the build and a fast response when a station fights back. That is the difference between a launch that drifts and a launch that ships.

Why It Runs Through the End of the Year

Start ASAP, run through year-end — that timing is not vague, it is the actual shape of a line build. Install comes first: mechanical and electrical, robots on their pedestals, cameras and scanners mounted and wired. Then integration: the PLC talking to every robot and every sensor, the HMI screens built, the safety circuits proven. Then commissioning: running real parts, dialing in robot paths and vision thresholds, driving down false rejects until the line trusts itself. Then ramp and sign-off. That arc does not compress into a two-week visit — it is roughly six months of steady, well-paid contract work, which is why the posting asks for engineers who can commit through the end of the year, not just drop in for a phase.

The Stack You Will Actually Be On

This is a North American line stack, and a deep one: Allen-Bradley / Rockwell for the controls — Studio 5000, FactoryTalk, the HMIs; Fanuc robots on the R-30iB controller for the material handling; and Keyence 3D vision — LJX-class laser-profile scanning — for the dimensional and seating checks. If those names are your daily tools, this contract is squarely in your lane. If you are strong on two of the three, a crew of four is exactly where you grow the third, on a real line, with people who know it.

The Contract, In One Place

Role: Controls Engineer — four openings
Scope: install and commission a new automated tire assembly line in automotive manufacturing
Stack: Allen-Bradley PLCs & HMIs (Studio 5000, FactoryTalk) · Fanuc robots (R-30iB) · Keyence 3D vision
Location: Ford KCAP — Kansas City, MO
Rate: $76/hr + travel expenses
Timing: starts ASAP; runs through the end of the year

View & Apply — Contract #3614

Hiring a Crew Without a Recruiter in the Middle

Staffing four niche controls engineers for a six-month build is exactly the kind of search that eats weeks when it runs one phone call at a time. On Automate America the customer posts the line directly and applications reach the customer directly; the network is organized by occupation and skill, so engineers who run Allen-Bradley, Fanuc and Keyence are findable in minutes, not after a month of calls. If you are standing up a line of your own, you can post a contract free — the rate, scope and exact stack go straight to the professionals who match them.