Hardware Design Manager

📍 Job Overview

Job Title: Hardware Design Manager

Company: Diversified Automation

Location: Louisville, KY

Job Type: Full Time

Category: Engineering Management / Operations Management

Date Posted: April 28, 2026

Experience Level: 5-10 years

Remote Status: On-site

🚀 Role Summary

• Oversee and manage complex hardware design projects for control systems within the material handling industry, ensuring adherence to scope, budget, and quality standards.

• Lead and mentor a team of hardware engineers, fostering a collaborative and high-performance engineering environment.

• Drive the design, development, and commissioning of motor control panels, PLC panels, and associated systems for material handling applications.

• Serve as a key technical liaison between sales, project management, customers, and engineering teams, contributing to sales support and customer relationship building.

• Implement and refine engineering processes and best practices to enhance design efficiency, cost-effectiveness, and project delivery timelines.

📝 Enhancement Note: This role is described as a "working manager" position, indicating a need for strong hands-on technical expertise in hardware design alongside leadership responsibilities. The focus on material handling applications (freight/parcel, baggage, warehouse distribution) suggests a need for understanding the unique operational demands and complexities of these sectors.

📈 Primary Responsibilities

• Manage the end-to-end hardware design process for conveyor motor control panels, PLC panels, and related systems, from initial concept through final commissioning.

• Coordinate with sales engineers and project managers to precisely define project specifications, scope, and design requirements, ensuring alignment with customer needs and sales agreements.

• Develop and maintain detailed drawing sets, including conveyor controls layouts, power feed calculations, 480V power schematics, 120V control schematics, I/O drawings, field device layouts, PLC and panel layouts, and design documentation.

• Prepare comprehensive material and equipment specifications for procurement, ensuring cost-effectiveness and adherence to design standards.

• Oversee the inspection, audit, and testing of completed motor control panels to guarantee sound construction and full compliance with design standards and specifications.

• Monitor and report on project costs versus allocated budgets, proactively managing expenses to stay within hardware and engineering financial targets.

• Travel to customer job sites as required for project discussions, support during installations, and troubleshooting, potentially assisting with sales activities.

• Cultivate and strengthen relationships between the sales department and other functional groups within the organization to promote seamless project execution and collaboration.

• Utilize computer-assisted engineering and design software (e.g., AutoCAD Electrical) to perform engineering tasks efficiently and potentially develop custom routines for automation.

• Provide technical guidance and troubleshooting support for complex operational issues, both internally and at customer sites.

📝 Enhancement Note: The responsibilities emphasize a blend of technical design, project oversight, cost management, and customer-facing interaction. The "working manager" aspect means the individual will likely be involved in the detailed design work themselves, not just delegation.

🎓 Skills & Qualifications

Education: Bachelor's Degree in Electrical Engineering (BSEE) or equivalent.

Experience:

• Over 5 years of similar hardware design experience in control systems, specifically for material handling applications.

Required Skills:

• Deep understanding and practical application of control system design principles for material handling and conveyor systems.

• Proficiency in designing motor control panels, PLC panels, and associated electrical systems.

• Expertise in power feed calculations, conduit and wire sizing, and adherence to electrical codes and standards.

• Advanced proficiency in AutoCAD and AutoCAD Electrical, with the ability to create custom routines for automation and efficiency.

• Strong knowledge of Allen-Bradley discrete products, Rockwell PLCs (ControlLogix, CompactLogix), and operator interface devices.

• Experience with Rockwell, Schneider, and Siemens Variable Frequency Drives (VFDs).

• Familiarity with communication bus design, including ControlNet, DeviceNet, Profibus, and Ethernet/IP.

• Ability to prepare detailed drawing sets including power schematics (480V), control schematics (120V), I/O drawings, and panel layouts.

• Experience in panel commissioning and checkout procedures.

• Proficient with Microsoft Office Suite (Word, Project, Excel), including linking Excel files within AutoCAD.

• Strong troubleshooting skills to diagnose and resolve technical issues.

• Excellent active listening, communication, and interpersonal skills.

• Demonstrated achievement orientation, bias for action, and drive for excellence.

• Critical thinking and complex problem-solving abilities.

Preferred Skills:

• Motion control design experience.

• Experience with Siemens, Beckhoff, and Schneider PLCs and VFDs.

• Experience with new standards of Ethernet/IP.

• Ability to travel to customer job sites and support sales activities.

📝 Enhancement Note: The requirements clearly delineate between core technical competencies in electrical hardware design for automation and essential leadership/management skills. The emphasis on specific product lines (Rockwell, Siemens, Schneider) and AutoCAD Electrical highlights the need for specialized technical acumen.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Showcase a minimum of 2-3 complex hardware design projects within the material handling or automation sector.

• For each project, clearly articulate the design challenges, the solutions implemented, and the specific technologies used.

• Include examples of detailed drawing sets (e.g., schematics, panel layouts, I/O diagrams) demonstrating technical proficiency.

• Highlight instances where custom AutoCAD routines or automation techniques were employed to improve design efficiency.

Process Documentation:

• Provide examples of design documentation, such as project specifications, Bill of Materials (BOMs), and testing protocols.

• Illustrate your approach to managing project costs and staying within hardware engineering budgets.

• Showcase your methodology for overseeing panel inspection, audit, and commissioning processes.

• Present how you ensure compliance with design standards and customer requirements throughout the project lifecycle.

• Include case studies where you successfully troubleshooted and resolved complex technical issues in the field.

📝 Enhancement Note: A strong portfolio is critical for this role, requiring tangible evidence of design capability, project management, and leadership. The emphasis on AutoCAD efficiency and specific automation technologies will be key differentiators.

💵 Compensation & Benefits

Salary Range: $100,000 - $140,000 annually (Estimate)

Benefits:

• Comprehensive health, dental, and vision insurance.

• 401(k) retirement plan with company match.

• Paid time off (PTO), including vacation, sick leave, and holidays.

• Opportunities for professional development and continued education.

• Potential for performance-based bonuses.

• Travel expense reimbursement for required site visits.

Working Hours: Standard 40-hour work week, with potential for overtime during peak project periods. Flexibility may be required due to project deadlines and customer needs.

📝 Enhancement Note: Based on industry benchmarks for Hardware Design Managers with 5-10 years of experience and significant team leadership responsibilities in a manufacturing/automation context in Louisville, KY, a salary range of $100,000 - $140,000 is estimated. This estimate considers the specialized technical skills, management duties, and the "working manager" aspect of the role. Benefits are typical for full-time engineering management positions.

🎯 Team & Company Context

🏢 Company Culture

Industry: Diversified Automation operates within the Automation and Manufacturing Technology sector, specifically focusing on providing advanced control systems for material handling applications. Their expertise lies in integrating hardware and software to create efficient, automated solutions for industries such as freight/parcel, baggage handling, warehouse distribution, automotive, and manufacturing. This context implies a culture that values innovation, precision, efficiency, and robust engineering solutions.

Company Size: Diversified Automation is likely a mid-sized to large enterprise, given the need for specialized management roles like Hardware Design Manager and the breadth of industries they serve. This size often means structured processes but also opportunities for significant impact and visibility for individuals.

Founded: The company's founding date (implied by the company URL and general industry presence) suggests a company with established experience and a track record in the automation market. This maturity typically translates to well-defined engineering practices and a stable operational framework.

Team Structure:

• The Hardware Design team likely comprises electrical engineers, drafters, and technicians specializing in control panel design, PLC integration, and power distribution.

• The Hardware Design Manager reports to the Director of Design and Hardware Engineering, indicating a clear hierarchy within the engineering department.

Methodology:

• Data-Driven Design: Emphasis on precise power calculations, component specifications, and adherence to stringent design standards.

• Process Optimization: Continuous improvement in design workflows, leveraging CAD tools for efficiency and accuracy.

• Project Management Integration: Close coordination with project managers to track costs, schedules, and scope adherence.

• Customer-Centric Solutions: Designs are tailored to meet specific customer requirements and operational needs in material handling.

Company Website: https://diversified-automation.com/ (Inferred from domain_derived)

📝 Enhancement Note: The company's industry and specialization suggest a fast-paced, technically demanding environment where precision and reliability are paramount. The "working manager" role implies a culture that values hands-on contribution and technical depth at all levels.

📈 Career & Growth Analysis

Operations Career Level: This role represents a mid-to-senior level position within the engineering management track. It requires a blend of advanced technical expertise in hardware design for automation and proven team leadership capabilities. The scope involves managing significant projects, directly impacting operational efficiency and client satisfaction.

Reporting Structure: The Hardware Design Manager reports directly to the Director of Design and Hardware Engineering. This structure indicates a clear line of accountability and provides a pathway for mentorship and career progression within the broader engineering leadership team.

Operations Impact: The Hardware Design Manager's work is critical to the successful implementation of automated material handling systems. Effective designs ensure system reliability, efficiency, and safety, directly contributing to the company's reputation, client success, and revenue generation through timely and cost-effective project delivery. Poor design can lead to costly project delays, equipment failures, and customer dissatisfaction.

Growth Opportunities:

• Leadership Advancement: Potential to move into higher management roles, such as Director of Engineering, overseeing broader design disciplines or multiple engineering teams.

• Technical Specialization: Opportunity to deepen expertise in specific areas like motion control, advanced automation technologies, or specific industry verticals within material handling.

• Cross-Functional Leadership: Transition into roles that manage larger, more complex programs integrating hardware, software, and project management.

• Process Improvement Leadership: Lead initiatives focused on optimizing the entire hardware design lifecycle, from sales handoff to final commissioning.

📝 Enhancement Note: The role offers a clear path for growth, blending technical and managerial development. The "working manager" aspect provides a unique opportunity to maintain technical relevance while developing leadership skills, making it an attractive position for technically proficient engineers looking to move into management.

🌐 Work Environment

Office Type: This is an on-site role requiring the Hardware Design Manager to work from the company's Louisville, KY office. The environment is expected to be a professional office setting, likely with dedicated engineering workstations and collaborative spaces.

Office Location(s): Louisville, Kentucky, United States. This location offers access to a skilled workforce and is a strategic hub for logistics and manufacturing industries.

Workspace Context:

• Dedicated Workstations: Engineers will have access to powerful computers equipped with specialized software like AutoCAD Electrical and other CAD/CAE tools.

• Collaborative Spaces: The office will likely feature meeting rooms and open areas for team discussions, design reviews, and cross-functional collaboration with sales and project management.

• Access to Resources: Proximity to technical documentation, component suppliers, and potentially internal testing or prototyping facilities.

• Team Interaction: The on-site nature facilitates direct interaction with the hardware engineering team, fostering a strong sense of camaraderie and enabling efficient problem-solving.

Work Schedule: The standard work schedule is 40 hours per week, typical for a full-time salaried position. However, the dynamic nature of project deadlines in the automation industry means that flexibility and potential for overtime may be required to meet client commitments and ensure timely project completion, especially during critical design or commissioning phases.

📝 Enhancement Note: The on-site requirement is crucial for this role, emphasizing the need for direct team supervision, hands-on involvement, and immediate collaboration within the engineering department and with other internal functions.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: A brief call with HR or a recruiter to assess basic qualifications, experience, and cultural fit.

• Technical Interview(s): In-depth discussions with the Director of Design and Hardware Engineering and potentially senior engineers. Expect questions on control system design principles, PLC systems, AutoCAD Electrical proficiency, power distribution, and troubleshooting scenarios.

• Managerial/Leadership Interview: Assessment of leadership style, team management experience, project management capabilities, and problem-solving approaches. This may include behavioral questions.

• Portfolio Review: A dedicated session where candidates present selected projects from their portfolio. Be prepared to walk through schematics, panel layouts, design choices, and demonstrate how you managed technical challenges and project constraints.

• Final Interview: Potentially with a senior leader or Director to discuss overall fit, strategic alignment, and expectations.

Portfolio Review Tips:

• Curate Strategically: Select 3-4 of your most impactful hardware design projects that best represent your technical skills, leadership, and experience in material handling automation.

• Focus on Impact: For each project, clearly articulate the problem statement, your role, the technical solutions you implemented, the specific tools and technologies used (especially AutoCAD Electrical and PLCs), and the quantifiable results (e.g., cost savings, efficiency gains, time reduction).

• Showcase Leadership: If possible, highlight projects where you managed a team, mentored junior engineers, or significantly influenced design decisions.

• Technical Depth: Be prepared to explain complex schematics, power calculations, and design choices in detail. Demonstrate your understanding of standards and best practices.

• Visual Aids: Use clear, well-organized visual aids (drawings, diagrams, photos) to support your presentation. Ensure your AutoCAD work is presented cleanly.

• Address Project Constraints: Discuss how you managed budgets, timelines, and unforeseen challenges.

Challenge Preparation:

• Design Scenario: Be ready for a hypothetical design challenge or a problem-solving scenario related to control panel design or automation systems. Think about how you would approach it, what information you would need, and the steps you would take.

• AutoCAD Electrical Automation: Consider how you would approach automating repetitive tasks in AutoCAD Electrical. Be ready to discuss potential custom routines or LISP applications.

• Troubleshooting: Prepare to discuss your methodology for troubleshooting complex electrical control system failures on a job site or in a panel.

📝 Enhancement Note: The interview process will heavily weigh technical proficiency in hardware design for automation, coupled with demonstrated leadership and project management skills. The portfolio review is a critical component, requiring candidates to effectively communicate their technical contributions and management approach.

🛠 Tools & Technology Stack

Primary Tools:

• AutoCAD Electrical: Essential for creating detailed electrical schematics, panel layouts, and wiring diagrams. Proficiency in creating custom routines or automation scripts within AutoCAD is highly valued.

• PLC Programming Software: Experience with Rockwell's RSLogix/Studio 5000 (for ControlLogix, CompactLogix) is a must. Familiarity with Siemens (TIA Portal), Beckhoff, or Schneider Electric programming environments is a significant plus.

• Variable Frequency Drive (VFD) Configuration Software: Tools for configuring and troubleshooting Rockwell, Schneider, and Siemens VFDs.

• CAD/CAE Software: General Computer-Aided Design and Engineering software for electrical design and simulation.

Analytics & Reporting:

• Microsoft Excel: For power calculations, BOM management, cost tracking, and data analysis. Ability to link Excel data with AutoCAD is beneficial.

• Microsoft Project: For project planning, scheduling, and tracking progress against timelines.

• ERP/MRP Systems: Potentially used for material procurement and inventory management, though direct user experience might not be required, understanding the data flow is helpful.

CRM & Automation:

• CRM Systems (e.g., Salesforce, HubSpot): While not a direct user role, understanding how sales scopes and customer requirements are managed and communicated is important for collaboration.

• Internal Ticketing/Project Management Systems: For tracking tasks, issues, and project progress within the organization.

📝 Enhancement Note: The core technical stack revolves around electrical design software (AutoCAD Electrical) and PLC/VFD programming/configuration tools. Proficiency with the specified Rockwell products is non-negotiable, with broader experience being a strong advantage.

👥 Team Culture & Values

Operations Values:

• Excellence & Drive: A strong emphasis on achieving high standards in design quality, project execution, and customer satisfaction. This is reflected in the "drive for Excellence and a Bias for Action" attribute.

• Problem-Solving & Critical Thinking: Valuing individuals who can logically analyze complex issues, identify root causes, and develop effective, robust solutions.

• Collaboration & Communication: Fostering an environment where team members work together effectively, share knowledge, and communicate clearly with internal and external stakeholders. This is crucial for a "working manager" role that bridges technical teams and business functions.

• Efficiency & Innovation: Encouraging the use of technology and creative approaches to streamline design processes, reduce costs, and deliver innovative solutions. The desire for custom AutoCAD routines exemplifies this.

• Integrity & Work Ethic: A fundamental expectation of honesty, reliability, and a strong commitment to work responsibilities. "Great Attitude, Work Ethic and Common Sense are a MUST" highlights this.

Collaboration Style:

• Cross-Functional Integration: The role requires active collaboration with sales to understand project scope, project managers for scheduling and cost control, and potentially software engineers and field service teams to ensure seamless integration of hardware solutions.

• Team-Oriented Problem Solving: Encouraging open discussion and collective brainstorming to tackle complex design or troubleshooting challenges.

• Feedback and Continuous Improvement: A culture that likely embraces constructive feedback to refine designs, processes, and team performance.

• Knowledge Sharing: Facilitating the exchange of technical expertise and best practices within the hardware design team.

📝 Enhancement Note: The company culture appears to be results-oriented, technically focused, and team-driven. The emphasis on specific attributes like "Bias for Action" and "Great Attitude" suggests a dynamic and demanding, yet supportive, work environment.

⚡ Challenges & Growth Opportunities

Challenges:

• Balancing Technical Depth and Management: As a "working manager," the primary challenge will be effectively allocating time between hands-on design work, team leadership, and administrative/managerial duties.

• Managing Project Scope Creep: Ensuring that project specifications are clearly defined and adhered to, preventing uncontrolled changes that can impact timelines and budgets.

• Keeping Pace with Technology: The automation industry evolves rapidly; staying current with new PLC platforms, communication protocols, and design tools is an ongoing challenge.

• Cross-Functional Alignment: Ensuring consistent communication and alignment between engineering, sales, and project management teams to avoid misunderstandings and ensure project success.

• Travel Requirements: Balancing on-site office responsibilities with necessary travel to customer job sites for project discussions and support.

Learning & Development Opportunities:

• Advanced Technical Training: Opportunities to gain certifications or specialized training in new PLC platforms, VFD technologies, or motion control systems.

• Leadership Development Programs: Formal or informal training in management techniques, strategic planning, and team motivation.

• Industry Conferences and Trade Shows: Attending events to stay abreast of the latest automation technologies, network with peers, and identify potential innovations for Diversified Automation.

• Mentorship: Learning from senior leadership within the company and potentially mentoring junior engineers, further solidifying technical and leadership skills.

• Process Improvement Initiatives: Leading projects to optimize the hardware design workflow, implement new tools, or enhance quality control procedures.

📝 Enhancement Note: The challenges are typical for a hybrid technical/management role in a dynamic industry. The growth opportunities are well-defined, offering a clear path for both technical specialization and career advancement into broader leadership positions.

💡 Interview Preparation

Strategy Questions:

• "Describe a complex hardware control system you designed for a material handling application. What were the key technical challenges, how did you overcome them, and what was the outcome?" (Focus on technical depth, problem-solving, and quantifiable results.)

• "Walk me through a project where you managed a team of engineers. How did you delegate tasks, monitor progress, and ensure project success while also contributing technically?" (Assess leadership, delegation, and "working manager" capability.)

• "How do you approach cost management and budget adherence for hardware design projects? Provide an example of a time you had to make trade-offs to stay within budget." (Evaluate financial acumen and decision-making.)

• "Imagine a situation where sales scope and the technical feasibility of a project are misaligned. How would you facilitate a resolution between sales and engineering?" (Test communication, negotiation, and cross-functional collaboration skills.)

Company & Culture Questions:

• "What do you know about Diversified Automation and our role in the material handling industry?" (Demonstrate research and genuine interest.)

• "How would you describe your leadership style, especially in a 'working manager' capacity?" (Align your style with the company's needs.)

• "What are your expectations regarding collaboration with other departments like Sales and Project Management?" (Show understanding of cross-functional importance.)

Portfolio Presentation Strategy:

• Structure Your Narrative: For each project, use a STAR (Situation, Task, Action, Result) or similar framework. Clearly articulate the business problem, your specific role and responsibilities, the actions you took (design steps, team management, problem-solving), and the measurable results.

• Highlight Technical Expertise: Be ready to deep-dive into schematics, panel layouts, component selections, and power calculations. Explain why you made certain design choices.

• Emphasize Management Contributions: Showcase instances where you led a team, mentored junior engineers, managed project timelines, or contributed to cost control.

• Showcase AutoCAD Efficiency: If you developed custom routines, be prepared to explain their function and the efficiency gains they provided.

• Quantify Impact: Whenever possible, use numbers to demonstrate the value of your work (e.g., percentage reduction in design time, cost savings, increase in system uptime).

Challenge Preparation:

• Design Problem: Practice sketching out a basic control panel schematic for a common material handling scenario (e.g., a simple conveyor motor control).

• Troubleshooting Scenario: Think through a process for diagnosing a PLC failure or a VFD malfunction in a complex system.

• AutoCAD Automation Ideas: Brainstorm ways to automate common tasks in AutoCAD Electrical (e.g., creating symbol libraries, generating BOMs from drawings).

📝 Enhancement Note: Prepare to articulate your technical design process, leadership philosophy, and project management approach. The portfolio presentation is a key opportunity to demonstrate your capabilities visually and verbally.

📌 Application Steps

To apply for this Hardware Design Manager position:

• Submit your application through the provided link on jobs.lever.co.

• Tailor Your Resume: Highlight experience in hardware design for material handling, control systems, PLC integration, AutoCAD Electrical proficiency, and team leadership. Quantify achievements wherever possible (e.g., "Managed a team of 5 engineers," "Reduced design time by 15% using custom AutoCAD scripts").

• Prepare Your Portfolio: Select 3-4 key projects that showcase your technical design skills, project management experience, and leadership capabilities. Ensure it includes examples of schematics, panel layouts, and a clear explanation of your process and results.

• Research Diversified Automation: Understand their market position, the industries they serve, and their product offerings. This will help you tailor your responses and ask insightful questions.

• Practice Your Presentation: Rehearse presenting your portfolio projects, focusing on clear communication, technical accuracy, and demonstrating leadership. Be ready to explain your design decisions and problem-solving strategies.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.

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