German — Controls Engineer
Jesus
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Industries Served
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Work History on Automate America
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- Photo ID✓ On file
Achievements
1
Skills
Programming Skills (7)
Controller: KRC4 | KRC5 Software: KUKA System Software (KSS) Level: Senior (Programmer)
Controller: IRC5 Software: RobotWare 5 | RobotWare 6 Level: Senior (Programmer)
Controller: R-30iB Plus / Software: FANUC OS | HandlingTool Level: Junior (Programmer)
AutoCAD: Basic–Intermediate (practical / field experience) AutoCAD: Intermediate – application-oriented AutoCAD (2D drafting – practical use)
PLC Programming & Controls Siemens PLC – TIA Portal V15.1 / V19 Project development under standard Network creation and device configuration PLC hardware setup and I/O integration Partial development of process sequences and control logic
PLC Programming & Control Systems Schneider Electric PLC / Basic to Intermediate programming
Machine Vision Systems Cognex In-Sight Camera setup and basic vision job configuration Pattern recognition and inspection tools (basic) PLC communication and I/O integration Support during commissioning and production startup
About Me
Control Engineer with 5+ years of experience in OEM automotive projects, specializing in robot programming, PLC integration, commissioning, and production launch with FANUC, KUKA, and ABB systems.
Skilled Trades (3)
On-site support during production, startup and ramp-up of automated manufacturing lines. Troubleshooting of PLCs, robots and automation equipment to minimize downtime. Collaboration with maintenance and operations teams to restore production safely and efficiently.
Functional validation of automation systems during installation and commissioning. Verification of I/O signals, sequences, safety interlocks and process conditions. Support of system readiness prior to SOP and production release.
Identification and implementation of process and control improvements in automated systems. Optimization of sequences, cycle times and system reliability. Support of root-cause analysis and corrective actions in production environments.
Professional Competencies (9)
On-site technical support during installation, commissioning and production activities. Communication with customer personnel using basic to intermediate English (B1) in technical environments. Support focused on troubleshooting, system validation and production continuity. Ability to follow instructions, clarify technical issues and escalate when required.
Support in industrial automation design, including control concepts and basic CAD documentation. Creation and modification of simple AutoCAD drawings and safety placards for manufacturing environments. SolidWorks Certified Associate (CSWA) with practical experience in 3D part and assembly modeling. Creation of mechanical models for automation and manufacturing support. Export of SolidWorks 3D models to DWG for documentation and integration with AutoCAD. Support of design modifications during installation and commissioning activities.
Application of industrial automation engineering principles in automotive manufacturing environments. Integration of PLCs, robots, vision systems and electrical components to support production processes.
On-site installation support, system bring-up and commissioning of automated equipment. Debugging of PLC, robot and field devices during startup and production ramp-up.
Hands-on experience supporting automotive manufacturing lines during installation, launch and production. Understanding of production flow, cycle time, safety requirements and OEM standards.
Development of PLC projects using Siemens TIA Portal V15.1 & V19 under standards. Network creation, device configuration, I/O integration and partial development of process sequences. Basic to intermediate programming support using Schneider Modicon (Unity Pro).
Troubleshooting of automation issues involving PLCs, robots and electrical components. Root-cause analysis and practical solutions to minimize downtime in production environments.
Implementation of control logic to manage automated manufacturing processes. Support of sequence logic, interlocks and process validation during commissioning and production.
Programming, commissioning and production support for industrial robots (ABB, FANUC, KUKA). Robot integration with PLCs, safety systems and peripheral equipment in body shop and powertrain applications.
Applications (9)
Robotic automation for assembly operations, ensuring accurate positioning, repeatability, and reliable part interaction.
Commissioning of robotic cells including mastering, calibration, TCP setup, frame definition, process validation, and SOP readiness.
Development of robotic programs including motion logic, tool coordination, process sequencing, and optimization of robot paths for production efficiency.
Robot-focused HMIs for cell status, alarms, manual recovery, and production monitoring.
Integration of industrial robots with tooling, weld equipment, conveyors, vision systems, and safety devices within automated cells.
Robotic material handling programming for palletizing, loading/unloading, and part transfer with optimized cycle times.
Implementation of robotic process checks, weld verification logic, and fault-proofing to ensure consistent quality.
Advanced troubleshooting of robot programs, motion faults, process errors, and communication issues to minimize production downtime.
Programming and commissioning of robotic spot welding and stud welding processes following automotive OEM standards.
My Business
Why Choose Me
<p>I bring hands-on experience supporting automation projects for <strong>automotive OEMs such as BMW, Volkswagen and Ford</strong>, working mainly with <strong>KUKA and ABB robots</strong> in applications including <strong>spot welding, stud welding and palletizing</strong>.</p> <p>I have participated in installation, commissioning and production ramp-up activities, integrating robots with PLCs, safety systems and peripheral equipment under OEM standards. I am a practical, plant-oriented engineer who adapts quickly to real production conditions, focuses on problem solving, and works effectively with multidisciplinary teams to deliver stable and reliable automation systems.</p>
Work Experience(4)
Senior Controls Engineer – PLC & Robotics Led programming, commissioning, and optimization of PLC and robotic systems for automated production lines. Expert in PLCs (Siemens) and robots (ABB, KUKA) with full PLC–robot integration. Designed and validated communication, interlocks, and safety systems (PLC Safety / ABB SafeMove). Supported SOP, production stability, and continuous improvement at plant level. Resolved complex control and robot issues through advanced debugging and root cause analysis.
Controls Engineer – Robotics & Automation Programmed, commissioned, and supported industrial robots (ABB, KUKA) in production environments. Integrated robots with PLC control systems, safety circuits, and plant communication networks. Performed robot startup, teaching, signal mapping, and interlock validation. Configured and validated robot safety systems (ABB SafeMove / KUKA safety) according to plant standards. Troubleshot robot motion, safety, and PLC-robot communication issues during SOP and production support. Optimized robot paths and sequences to improve cycle time, line stability, and uptime.
Engineering Manager – Plant Operations & Manufacturing Engineering Led plant engineering and operations support for automated production lines (PLC & robotics). Managed process engineering, production support, and continuous improvement initiatives at plant level. Coordinated engineering, maintenance, production, and quality teams to ensure line stability and uptime. Drove cycle time optimization, downtime reduction, and OEE improvement across manufacturing processes. Ensured compliance with safety standards, operational procedures. Delivered measurable improvements in operational performance.
Robotics Programmer (KUKA & ABB) – Semi-Senior Programmed and commissioned KUKA and ABB robots for welding, material handling, and assembly applications. Performed robot startup, teaching, signal mapping, and PLC integration (Siemens / Rockwell). Optimized robot motions and sequences to improve cycle time and production stability. Configured and validated robot safety systems (ABB SafeMove / KUKA safety). Debugged robot–PLC communication and interlocks during SOP and production ramp-up. Supported successful production launches under automotive OEM standards.
Education / Training / Certificates(3)
(SafeMove Pro),
Fundamentals of KUKA robot programming (KRL) KMC-T##1217
ID # C-DTWA5KXUN2
Facilities Worked At(8)
Frequently Asked Questions
- What does a Controls Engineer do?
- A Controls Engineer designs, programs, and maintains automated control systems including PLCs, HMIs, SCADA systems, and industrial robots. They work in manufacturing, automotive, and process industries to optimize production and ensure system reliability.
- What certifications do Controls Engineers need?
- Common certifications include Rockwell Automation Certified Professional, Siemens Certified Professional, FANUC Robot certifications, ABB Robot Programming certifications, and TIA Portal certifications. Industry experience is often valued as highly as certifications.
- How do I hire a Controls Engineer?
- On Automate America, you can search for Controls Engineers by skill, location, and availability. Post a contract with your requirements, review applicant profiles and certifications, then connect directly or use White Glove managed services.
- What does German do?
- German is a Controls Engineer on Automate America, the global professional marketplace for skilled talent across industrial, commercial, and residential work.
- Where is German located?
- German is based in Fenton, Michigan.
- What does German specialize in?
- German works with KUKA, ABB, Fanuc, Autodesk, Siemens as a Controls Engineer on Automate America, the global professional marketplace for skilled talent across industrial, commercial, and residential work.
- Is German available for work?
- Availability unknown. German has not marked it recently.
- How do I connect with or hire German?
- Create a free profile on Automate America and send a connection or contract request from this profile. German can then respond and coordinate the work directly through the platform.