Automation Engineer

Position Purpose

The Automation Engineer is responsible for ensuring the safe, reliable, and efficient operation of all automation, PLC, robotic, and material handling systems within the plant. The role provides hands-on technical leadership in PLC programming, robotics, AGV/EGV systems, and industrial automation, directly supporting maintenance reliability, reduction of unplanned downtime, and continuous improvement initiatives.

This position acts as a technical authority and enabler for maintenance and production teams, supporting automation-driven productivity, data accuracy, and long-term asset reliability.

Organizational Alignment

1. Reports functionally and operationally to the Maintenance Manager
2. Works closely with:
   • Maintenance Technicians and PLC Technician
   • Production and Engineering teams
   • External integrators, OEMs, and service providers
3. Supports plant-level CAPEX, reliability, safety, and Lean transformation initiatives

Key Responsibilities

Automation, PLC & Control Systems

1. Design, program, modify, and troubleshoot PLCs, HMIs, and SCADA systems (Allen-Bradley, Siemens preferred).
2. Develop and maintain control logic, sequencing, interlocks, alarms, and safety functions.
3. Ensure optimal performance and availability of:

• • Automated production lines
  • Robotic systems
  • AGV / EGV and automated material handling systems

      5. Lead advanced troubleshooting of automation-related failures to minimize downtime.

      6. Maintain version control, backups, and change management for all automation programs.

Robotics & Automation Design

1. Support or lead robot design, integration, and modification, including end-of-arm tooling and safety interfaces.
2. Maintain and optimize motion control, servo systems, drives, and vision systems.
3. Identify opportunities to replace manual processes with automation to improve safety, quality, and productivity.

Maintenance, Reliability & Execution

1. Support the development and execution of Preventive Maintenance (PM) plans for automation, PLCs, robotics, and AGV/EGV systems.
2. Define automation-specific PM tasks, frequencies, spare parts, and technical standards in CMMS.
3. Actively support breakdown response and emergency troubleshooting.
4. Participate in and technically lead RCFA for automation-related failures.
5. Contribute to improvement of MTBF, MTTF, OEE, and reduction of unplanned downtime.

CAPEX, Projects & Continuous Improvement

1. Support or lead automation-related CAPEX projects, including:
   • Scope definition
   • Technical evaluation
   • Installation, commissioning, and validation
2. Support FAT/SAT activities and contractor supervision.
3. Identify and implement automation and Industry 4.0 opportunities aligned with Lean principles.
4. Standardize automation hardware, software, and design approaches across the plant.

Safety, Compliance & Standards

1. Ensure all automation systems comply with:
   • OSHA regulations
   • Vesuvius Group standards
   • Electrical and machine safety requirements
2. Support LTT, machine guarding, and safety PLC implementations.
3. Participate in audits, SCARs, and corrective actions related to automation and controls.
4. Design and maintain systems with safety by design principles.

 Documentation, CMMS & Knowledge Transfer

1. Create and maintain:
   • Electrical schematics
   • Control narratives
   • SOPs and technical documentation
2. Ensure automation assets, BOMs, spare parts, and documentation are properly maintained in CMMS.
3. Train and coach Maintenance Technicians, PLC Technician, and operators on automated systems.
4. Support cross-training to reduce single-point technical dependency.

Key Result Areas (KRAs)

1. Automation Reliability: Reduction of automation-related downtime and recurring failures.
2. Maintenance Effectiveness: Quality PM execution and improved asset reliability metrics.
3. Safety & Compliance: Zero serious safety incidents related to automation systems.
4. Operational Performance: Improved productivity, data accuracy, and process stability.
5. Capability Building: Increased automation and PLC competency within maintenance teams.

Education & Qualifications

• Bachelor’s degree in electrical engineering, Mechanical Engineering, Mechatronics, Automation Engineering, or equivalent experience.
• 3–5+ years’ experience in industrial automation, PLC programming, and system integration.
• Automation / PLC certifications preferred.
• Experience in a manufacturing and/or unionized environment preferred.

 Technical Skills & Experience

• PLCs: Allen-Bradley, Siemens
• HMI / SCADA development and troubleshooting
• Motor controls, VFDs, servo drives, motion control
• Robotics, AGV/EGV systems, vision systems
• Electrical schematics and control panel design
• CMMS usage for PMs, assets, and documentation
• CAD tools (SolidWorks, AutoCAD Electrical – preferred)

 Skills & Behaviors

• Strong hands-on, shop-floor orientation
• High ownership for equipment reliability and safety
• Structured problem-solving and analytical mindset
• Ability to work independently and manage multiple priorities
• Strong communication across maintenance, production, and engineering
• Willingness to challenge existing solutions constructively
• Discipline in standards, documentation, and execution