Mechatronics Engineer

The Mechatronics Engineer is responsible for supporting, improving, modernizing, and integrating automated manufacturing equipment within AFL cable manufacturing operations. The position provides advanced technical expertise in industrial controls, automation, electrical systems, motion control, machine integration, and equipment troubleshooting.

The engineer supports both existing manufacturing assets and new equipment installations, with primary responsibility for machine sustainability and controls modernization projects, PLC/HMI and drive upgrades, equipment integration, advanced troubleshooting, and equipment startup and commissioning.

The Mechatronics Engineer works closely with Maintenance, Process Engineering, Manufacturing Technology, Operations, OEMs, and outside integrators to ensure manufacturing equipment is safe, reliable, maintainable, and capable of meeting production requirements.

Responsibilities

Machine Improvement & Automation

• Execute machine improvement and automation projects in support of manufacturing, process, safety, quality, reliability, and operational objectives.
• Develop technical solutions in response to approved project requests from Operations, Process Engineering, EHS, Maintenance, Quality, and other manufacturing support functions.
• Translate defined project needs and performance objectives into controls, automation, electrical, and electromechanical solutions.
• Design, develop, program, integrate, and commission machine modifications involving PLCs, HMIs, drives, motion control, sensors, machine vision, laser measurement systems, safety systems, smart devices, and industrial communications.
• Collaborate with project requestors and other stakeholders to understand the problem, establish technical requirements, evaluate solution alternatives, and define the appropriate scope of work.
• Support projects intended to improve manufacturing performance, including equipment capability, throughput, RFT, scrap reduction, process control, safety, ergonomics, reliability, and operational efficiency.
• Develop machine improvements that enhance operator interfaces, diagnostics, alarm handling, process control, error-proofing, and equipment functionality.
• Coordinate technical implementation with Maintenance, Process Engineering, Operations, EHS, OEMs, integrators, and other resources as required.
• Validate completed modifications and confirm that the implemented solution meets the defined project objectives.
• Document machine modifications, controls changes, programming, drawings, settings, and other technical information required for long-term equipment support.

Machine Sustainability & Controls Modernization

• Identify and execute machine sustainability projects addressing obsolete, unsupported, or unreliable controls and automation components.
• Upgrade legacy PLCs, HMIs, variable frequency drives, servo systems, industrial networks, sensors, safety devices, and other machine-control hardware.
• Develop migration strategies for aging or obsolete control platforms while minimizing production risk and equipment downtime.
• Develop and modify PLC, HMI, SCADA, motion-control, and drive applications required for equipment upgrades and improvements.
• Integrate new controls and automation technologies into existing manufacturing equipment.
• Maintain appropriate backups and technical documentation for modified control systems.
• Improve equipment reliability, maintainability, diagnostics, and troubleshooting capability through controls and automation improvements.

Advanced Troubleshooting & Operational Support

• Serve as a technical resource for difficult or recurring equipment problems requiring advanced controls, electrical, automation, or electromechanical troubleshooting.
• Troubleshoot PLC-controlled equipment including I/O, industrial networks, sensors, VFDs, servo systems, motion control, safety circuits, HMIs, and associated electrical systems.
• Analyze equipment failures and recurring problems to determine root cause and develop sustainable corrective actions.
• Support Maintenance and Process Engineering when problems extend beyond normal maintenance troubleshooting capabilities.
• Use electrical schematics, PLC logic, OEM documentation, machine data, and diagnostic tools to systematically troubleshoot complex equipment problems.
• Assist in developing technical troubleshooting skills within Maintenance and other technical organizations.
• Provide technical support during critical equipment failures and production interruptions when required.

Equipment Startup, Commissioning & Integration

• Provide technical support for new OEM equipment installations and startups.
• Work directly with OEM technicians, controls engineers, integrators, Maintenance, Process Engineering, and Operations during machine commissioning.
• Review and troubleshoot OEM controls, electrical systems, PLC/HMI programs, drives, networks, instrumentation, and machine interfaces.
• Support acceptance testing and verify that equipment controls and functionality meet AFL requirements and purchase specifications.
• Integrate new OEM equipment with existing AFL equipment, controls, production systems, and supporting processes.
• Identify and resolve controls and automation issues discovered during startup and production ramp-up.
• Support post-startup debugging, optimization, and stabilization of new manufacturing equipment.

Equipment Relocation & Restart

• Provide controls and technical support following internal equipment relocations.
• Assist with machine reconnection, controls verification, I/O checkout, network communication, drive and motion-system verification, and functional testing.
• Debug equipment following relocation and resolve electrical, controls, communication, or integration problems created or discovered during the move.
• Support machine startup and return-to-production activities following relocation.
• Work with Maintenance, Process Engineering, Operations, and contractors to ensure relocated equipment is returned to a safe and reliable operating condition.

Engineering Documentation & Technical Standards

• Develop and maintain electrical drawings, controls documentation, PLC/HMI backups, network information, drive parameters, and other technical information required to support manufacturing equipment.
• Document modifications made to equipment and control systems.
• Review OEM documentation and controls architecture for new equipment and major upgrades.
• Help establish and maintain controls and automation standards for AFL manufacturing equipment.
• Ensure technical documentation is organized and usable by Engineering and Maintenance personnel.

Personal Qualities

• Collaboration- Able to translate manufacturing and operational needs into defined technical solutions and work effectively across Operations, Maintenance, Process Engineering, Manufacturing Technology, OEMs, and integrators.
• Organization / Work Management- Able to self-manage priorities, schedules, and technical work to meet project and production requirements.
• Technical Discipline- Verifies assumptions, checks work, maintains backups and documentation, collects appropriate data, and confirms equipment performance following modifications.
• Coaching & Development- Develops technical skills in self and others and shares controls, automation, and troubleshooting knowledge with technical personnel.
• Business Acumen- Understands how equipment reliability, throughput, quality, downtime, and maintainability affect manufacturing performance.
• Problem Solving / Improvement- Uses a systematic, multidisciplinary, and data-driven approach to complex equipment problems and continuous improvement.

Qualifications

• Bachelor's degree in Mechatronics Engineering, Electrical Engineering, Mechanical Engineering, Automation Engineering, or a closely related engineering discipline.
• Relevant engineering experience commensurate with the assigned Mechatronics Engineer level. Relevant internship/co-op experience will be considered when evaluating technical readiness, particularly for entry-level candidates.
• Strong electromechanical and industrial automation background with demonstrated ability to troubleshoot complex manufacturing equipment.
• Proficiency with industrial PLC platforms including Siemens, Allen-Bradley/Rockwell, and/or GE/Emerson.
• Ability to develop, troubleshoot, and modify PLC and HMI applications.
• Working knowledge of industrial communication networks including EtherNet/IP, PROFINET/PROFIBUS, and related industrial protocols.
• Working knowledge of variable frequency drives, AC vector drives, servo systems, motion control, electromagnetic braking, coordinated drives, and tension-control applications.
• Ability to read and troubleshoot electrical schematics and machine-control documentation.
• Experience with industrial sensors, instrumentation, safety systems, machine vision, and other smart automation devices.
• Experience with equipment commissioning, startup, and production debugging.
• Working knowledge of AutoCAD, SolidWorks, or similar engineering software is beneficial.
• Experience with SCADA, industrial data acquisition, and manufacturing connectivity systems is beneficial.
• Working knowledge of Microsoft Office Suite.

Working Conditions

Works in a manufacturing environment around automated production equipment and heavy machinery operating on a 24-hour, 7-day schedule. The position may require occasional after-hours support for equipment startups, major upgrades, commissioning activities, planned shutdowns, or critical equipment problems.