Automation Maintenance & Controls Specialist

What a day looks like

You arrive on the floor and bring work centers online, checking interlocks and alarms before production ramps. As the shift progresses, you execute quick changeovers, dial in adhesive dispense parameters, and swap solder tips or assembly fixtures. If a line stops, you triage fast—pneumatics, robotics, or sensors—documenting everything in the CMMS and escalating per site procedures. You complete barrel/drum changes, weight checks, and verify quality using gauges. Before handoff, you attend a crossover meeting and update equipment logs to keep the next team ready.

Environment & schedule

This role may run on irregular schedules. Expect exposure to chemicals, high voltage, loud noise, and hazardous waste. You’ll always follow company health, safety, and environmental policies and properly handle and dispose of hazardous materials.

Growing responsibilities by level

Level 1 — Core operations and rapid response

• Start up and shut down work centers; perform routine changeovers.
• Respond quickly to production issues to minimize downtime and keep assets available.
• Troubleshoot basics on pneumatics, soldering, robots, tip changers, and assembly fixtures.
• Execute tasks like barrel/drum changes, weight checks, and equipment changeovers.
• Understand production metrics and follow escalation procedures.
• Work with multiple adhesive types and resolve dispense issues.
• Document all repairs and PMs in the CMMS; communicate status in crossover meetings and logs.
• Comply with company HSE policies and applicable regulations; handle hazardous materials correctly.
• Perform other duties as assigned.

Level 2 — Advanced troubleshooting and program adjustments

• All Level 1 tasks, plus:
• Diagnose PLC programs, hydraulics, pneumatics, servo drives, and vision systems.
• Read and apply electrical schematics, pneumatic prints, and blueprints; replace hydraulic/pneumatic components.
• Rebuild solder heads and troubleshoot robot programs.
• Verify quality using gauging fixtures.
• Maintain strict adherence to HSE policies and regulations; handle hazardous materials properly.
• Perform other duties as assigned.

Level 3 — Programming, optimization, and technical leadership

• All Level 2 tasks, plus:
• Modify robot paths; teach/calibrate vision systems; implement HMI modifications.
• Create and modify PLC ladder logic, HMI applications, pneumatic diagrams, and electrical schematics.
• Apply GD&T, use precision metrology tools, and work with industrial network protocols.
• Optimize soldering processes and perform servo drive replacements.
• Contribute to engineering design through blueprint/drawing creation.
• Train and coach production and maintenance staff; support skills assessments and recommend or deliver training.
• Participate in problem-solving, continuous improvement, and departmental projects.
• Comply with HSE policies and regulations; handle hazardous materials correctly.
• Perform other duties as assigned.

Qualifications

Level 1

• 1–3 years in mechanical/automation machine repair.
• Proven ability to troubleshoot, update, and work on equipment in assigned areas.
• Solid mechanical foundation including pneumatics and electrical.
• Strong interpersonal and written/verbal communication; team-focused.
• English proficiency required; Spanish bilingual a plus.

Level 2

• Meets Level 1 requirements, plus:
• Associate’s degree in a technical field and/or significant relevant experience or apprenticeship (journeyman) with 2–3 years in an automation setting.
• 4–6 years of related experience troubleshooting and repairing automation, hydraulic, and electrical systems.
• Proficiency navigating PLC/HMI software, machine connectivity, and troubleshooting.
• Ability to modify existing Allen Bradley PLC programs and update HMI applications.
• Capability to adjust and optimize vision sensor programs.
• Hands-on industrial robotics experience (ABB preferred), including troubleshooting and minor program edits.
• Fluent reading of electrical schematics, blueprints, and pneumatic/hydraulic diagrams.

Level 3

• Meets Level 2 requirements, plus:
• 7+ years of progressive automation/maintenance experience with advanced programming and troubleshooting.
• Expertise rebuilding machinery and integrating hydraulic, pneumatic, electronic, and robotic systems.
• Advanced creation/modification of PLC ladder logic, HMI apps, and pneumatic/electrical diagrams.
• Proficiency in vision system calibration and advanced robot path modification.
• Knowledge of GD&T and precision metrology.
• Ability to contribute to design reviews and ensure compliance with codes, safety standards, and maintainability.

Physical demands

• Prolonged standing for at least 8 hours, up to 12 hours per day.
• Lift up to 35 lbs multiple times per hour.
• Frequent bending, twisting, turning, and lifting.
• Repetitive hand use: gripping, grasping, pinching, squeezing.

Core proficiencies

• Mechanical troubleshooting
• Preventive maintenance and inspections (CMMS-driven)
• Industrial robot programming
• Pneumatics troubleshooting
• Maintenance and repair
• CNC machine setup and changeover

Tools and technologies

• Programmable Logic Controllers (Allen Bradley)
• Human-Machine Interfaces (HMI)