Forge Controls Engineer – PLC / Robot / Virtual Commissioning

Location: Chennai
Experience: 2–6 Years
Qualification: Engineering degree/diploma – Electrical / Electronics / Automation / Mechatronics or related
Open Position : 02

Role Overview

We are looking for Controls Engineers to design, develop, test and virtually validate the complete automation controls architecture for the FORGE manufacturing cell, covering PLCs, collaborative robots, virtual commissioning, safety, HMI and validation.

Key Responsibilities

• Program and configure Siemens S7-1500 / S7-1500F PLCs for standard and safety logic using TIA Portal / STEP 7.
• Develop motion paths, safety zones, tool control and interface logic for FANUC and ABB collaborative robots.
• Develop modular, reusable and well-commented PLC logic in compliance with Ford / Plant Controls Standards.
• Integrate PLC, robots, HMI, sensors and actuators in a Virtual Commissioning environment using digital models.
• Build kinematic behaviours, sensors, actuators and physics into supplied 3D CAD models.
• Establish SiL / HiL connectivity and conduct comprehensive virtual factory acceptance testing.
• Validate automatic, manual and dry-run cycles, safety interlocks, E-stops, collaborative speed/zone changes and fault-injection scenarios.
• Configure and verify PROFINET, PROFIsafe, OPC UA and TCP/IP communications between PLCs, cobots, HMI and peripheral devices.
• Develop HMI/operator interfaces using Siemens WinCC; perform code reviews, static checks and naming-convention audits.
• Prepare vFAT execution reports, weekly progress updates, open-issue lists, burn-down charts and complete project handover documentation.

Mandatory Technical Skills

• Strong hands-on experience with Siemens S7-1500 / S7-1500F and TIA Portal / STEP 7 Professional / Safety Advanced.
• Experience with FANUC CRX/CR Series and/or ABB GoFa / CRB / YuMi collaborative robots.
• Experience with Siemens Tecnomatix Process Simulate, MCD, SIMIT or PLCSIM Advanced.
• Knowledge of functional safety, safety interlocks, E-stops, PROFIsafe and collaborative robot safety.
• Working knowledge of PROFINET, OPC UA and TCP/IP industrial communications.
• Ability to troubleshoot, validate and document automation controls in a manufacturing environment.

Preferred Skills

• FANUC DCS/TP and ABB SafeMove/RAPID experience.
• Experience with Siemens WinCC Unified / WinCC Comfort.
• Knowledge of ISO/TS 15066 and Ford Controls Standards.
• Experience in virtual FAT, SiL/HiL and digital manufacturing / virtual commissioning.

Candidate Profile

Controls / Automation Engineer with 2–6 years of relevant experience, strong Siemens PLC and robot programming fundamentals, virtual commissioning knowledge and the ability to work effectively with controls, robotics, simulation and manufacturing teams.

Key Skills: PLC Programming | Siemens S7-1500 | TIA Portal | FANUC | ABB | Cobot | Robot Programming | Process Simulate | MCD | SIMIT | PLCSIM Advanced | Virtual Commissioning | Functional Safety | PROFIsafe | PROFINET | WinCC | OPC UA

Project: Forge Controls Activity | Work Model: Engineering support / project-based

Send your CVs to [email protected]