Automation Engineer
Job DetailsDescription Position PurposeThe 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 AlignmentReports functionally and operationally to the Maintenance ManagerWorks closely with:Maintenance Technicians and PLC TechnicianProduction and Engineering teamsExternal integrators, OEMs, and service providersSupports plant-level CAPEX, reliability, safety, and Lean transformation initiativesKey Responsibilities Automation, PLC & Control SystemsDesign, program, modify, and troubleshoot PLCs, HMIs, and SCADA systems (Allen-Bradley, Siemens preferred).Develop and maintain control logic, sequencing, interlocks, alarms, and safety functions.Ensure optimal performance and availability of:Automated production linesRobotic systemsAGV / EGV and automated material handling systems Lead advanced troubleshooting of automation-related failures to minimize downtime. Maintain version control, backups, and change management for all automation programs. Robotics & Automation DesignSupport or lead robot design, integration, and modification, including end-of-arm tooling and safety interfaces.Maintain and optimize motion control, servo systems, drives, and vision systems.Identify opportunities to replace manual processes with automation to improve safety, quality, and productivity. Maintenance, Reliability & ExecutionSupport the development and execution of Preventive Maintenance (PM) plans for automation, PLCs, robotics, and AGV/EGV systems.Define automation-specific PM tasks, frequencies, spare parts, and technical standards in CMMS.Actively support breakdown response and emergency troubleshooting.Participate in and technically lead RCFA for automation-related failures.Contribute to improvement of MTBF, MTTF, OEE, and reduction of unplanned downtime.CAPEX, Projects & Continuous ImprovementSupport or lead automation-related CAPEX projects, including:Scope definitionTechnical evaluationInstallation, commissioning, and validationSupport FAT/SAT activities and contractor supervision.Identify and implement automation and Industry 4.0 opportunities aligned with Lean principles.Standardize automation hardware, software, and design approaches across the plant.Safety, Compliance & StandardsEnsure all automation systems comply with:OSHA regulationsVesuvius Group standardsElectrical and machine safety requirementsSupport LTT, machine guarding, and safety PLC implementations.Participate in audits, SCARs, and corrective actions related to automation and controls.Design and maintain systems with safety by design principles.Documentation, CMMS & Knowledge TransferCreate and maintain:Electrical schematicsControl narrativesSOPs and technical documentationEnsure automation assets, BOMs, spare parts, and documentation are properly maintained in CMMS.Train and coach Maintenance Technicians, PLC Technician, and operators on automated systems. Support cross-training to reduce single-point technical dependency. Key Result Areas (KRAs)Automation Reliability: Reduction of automation-related downtime and recurring failures.Maintenance Effectiveness: Quality PM execution and improved asset reliability metrics.Safety & Compliance: Zero serious safety incidents related to automation systems.Operational Performance: Improved productivity, data accuracy, and process stability.Capability Building: Increased automation and PLC competency within maintenance teams.Education & QualificationsBachelor’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 & ExperiencePLCs: Allen-Bradley, SiemensHMI / SCADA development and troubleshootingMotor controls, VFDs, servo drives, motion controlRobotics, AGV/EGV systems, vision systemsElectrical schematics and control panel designCMMS usage for PMs, assets, and documentationCAD tools (SolidWorks, AutoCAD Electrical – preferred)Skills & BehaviorsStrong hands-on, shop-floor orientationHigh ownership for equipment reliability and safetyStructured problem-solving and analytical mindsetAbility to work independently and manage multiple prioritiesStrong communication across maintenance, production, and engineeringWillingness to challenge existing solutions constructivelyDiscipline in standards, documentation, and execution