This role serves as a critical link between manufacturing engineering, controls, equipment suppliers, operations, maintenance, quality, and IT/OT teams to ensure automated equipment is successfully integrated into ONE's manufacturing environment and achieves required safety, quality, throughput, reliability, and operational performance.
The Automation Integration Engineer will provide hands-on technical leadership during equipment installation, commissioning, launch, and production ramp. The ideal candidate combines strong controls and automation expertise with practical manufacturing experience and is comfortable troubleshooting complex equipment directly on the production floor.
ESSENTIAL DUTIES AND RESPONSIBILITIES:
Automation & Controls Integration
- Integrate automated manufacturing equipment, controls, robotics, sensors, vision systems, and supporting technologies into ONE manufacturing operations
- Develop, modify, troubleshoot, and optimize PLC and HMI applications
- Support integration of PLCs, industrial networks, robots, drives, safety systems, vision systems, and manufacturing equipment
- Establish and validate communication between machines, production systems, manufacturing execution systems (MES), databases, and other plant-level systems as applicable
- Develop and maintain equipment communication standards and interface requirements
- Review electrical controls architecture, schematics, control panels, I/O configurations, network architecture, and equipment documentation
- Ensure automation solutions comply with ONE engineering standards and applicable industry requirements
Equipment Launch & Commissioning
- Participate in equipment design reviews and provide automation and controls input throughout the equipment development lifecycle
- Support Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), installation, commissioning, and production validation
- Work directly with machine builders and system integrators to resolve controls, programming, communication, and equipment performance issues
- Lead or support equipment debug during installation and production ramp
- Verify equipment meets defined cycle time, uptime, quality, safety, and process capability requirements after final acceptance
- Identify integration risks early and develop mitigation plans after equipment reaches the production floor
- Support equipment handoff from Advanced Manufacturing Engineering to Operations and Maintenance
Robotics & Advanced Automation
- Integrate and troubleshoot industrial robotic systems used for material handling, assembly, dispensing, inspection, welding, and other automated processes
- Support programming and optimization of robotic applications
- Integrate machine vision, barcode/RFID, traceability, sensors, servo systems, drives, and automated material handling equipment
- Support implementation of collaborative robotics and other advanced manufacturing technologies where appropriate
- Evaluate new automation technologies that can improve safety, quality, productivity, flexibility, or manufacturing cost
Troubleshooting & Production Support
- Provide advanced technical support for automation and controls issues affecting production
- Troubleshoot PLC logic, industrial networks, robotics, sensors, servo systems, drives, safety circuits, machine vision, and electrical controls
- Lead structured root cause analysis for recurring automation-related downtime
- Implement permanent corrective actions rather than relying on temporary equipment fixes
- Analyze equipment downtime and performance data to identify opportunities for improvement
- Partner with Maintenance and Operations to improve Mean Time Between Failure (MTBF) and Mean Time to Repair (MTTR)
- Provide escalation support for complex equipment failures
Manufacturing Systems Integration
- Support integration between production equipment and MES, SCADA, historian, traceability, and manufacturing data systems
- Ensure equipment generates accurate and reliable production, quality, process, and traceability data
- Partner with IT/OT and cybersecurity resources to ensure industrial networks and connected equipment meet ONE requirements
- Support standardized communication protocols and data structures across manufacturing equipment
- Participate in Industry 4.0 and smart manufacturing initiatives
Equipment Standards & Documentation
- Develop and maintain ONE automation and controls standards
- Review supplier equipment designs for compliance with ONE specifications
- Maintain PLC programs, HMI applications, robot programs, electrical drawings, network documentation, backups, and revision history
- Develop troubleshooting guides and technical documentation for Maintenance and Operations
- Support creation of spare-parts strategies for critical automation components
- Ensure equipment changes follow appropriate change-control processes
Continuous Improvement
- Identify opportunities to improve equipment cycle time, uptime, quality, ergonomics, and reliability
- Use manufacturing and equipment data to identify chronic losses and improvement opportunities
- Support automation upgrades and equipment modifications