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 team-oriented 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

📌 Forge Controls Engineer (Chennai)
🏢 CS Tech AI
📍 Chennai