Maintenance Automation Sr. Engineer

About the Role:
The Maintenance Automation Sr. Engineer (PLC) plays a critical leadership role in developing, commissioning, optimizing, and sustaining advanced automation systems within a high-volume automotive Paint Shop environment. This position ensures seamless integration and high performance of robotic, PLC, HMI, and SCADA systems across all major paint processes—including pre-treatment, e-coat, primer, basecoat, clearcoat, ovens, and final inspection. The engineer oversees the full automation lifecycle, from system specification and programming to commissioning, troubleshooting, and continuous improvement. Working closely with maintenance, controls, quality, and production teams, this role ensures that automation systems meet uptime, quality, safety, and throughput targets while complying with OEM standards and regulatory requirements.

Key Responsibilities:

• Automation System Design & Programming
  • Design and implement control strategies for robotic and automated systems in paint booths, sealer areas, and utilities.
  • Develop, modify, and optimize PLC logic using Siemens S7/TIA Portal, Allen-Bradley, Beckhoff.
  • Program and refine robot paths and paint parameters for ABB IRB5500, Fanuc R-2000iC, KUKA KR series, Dürr EcoRP.
  • Design and integrate HMI/SCADA interfaces for alarms, diagnostics, and real-time data visualization.

• Commissioning & Project Execution
  • Lead automation commissioning for new installations, upgrades, and expansions in the paint shop.
  • Support FAT/SAT, I/O validation, safety interlock testing, and functional verification.
  • Optimize takt time, cycle time, and line balancing during ramp-up phases.

• Integration & Data Systems
  • Integrate automation systems with MES, QMS, SCADA, and traceability platforms.
  • Support vision systems for defect detection and robotic path correction.
  • Deploy and maintain OPC-UA/MQTT and IoT-based monitoring systems.

• Process Monitoring & Optimization
  • Analyze KPIs such as FTQ, uptime, overspray, paint usage, rework rates.
  • Implement automation-driven improvements to reduce energy and material consumption.
  • Develop predictive maintenance strategies using historical automation data.

• Safety, Quality & Compliance
  • Ensure compliance with CE, ISO 13849, OSHA, NFPA 79, and other safety standards.
  • Conduct risk assessments and update safety circuits (Pilz, Siemens, SICK).
  • Implement poka-yoke systems to prevent errors and enhance quality.
  • Support audits and certifications related to paint operations and automation.

• Documentation & Training
  • Create and maintain electrical/pneumatic schematics (EPLAN), PLC/HMI backups, FMEA reports, and robot backups.
  • Develop SOPs and training modules for maintenance and production teams.
  • Maintain automation change logs and version control systems.

Skills:

• Technical Skills
  • PLC Expertise — Siemens, Allen-Bradley, Beckhoff.
  • Robotics — ABB, Fanuc, KUKA, Dürr paint robots.
  • SCADA/HMI — Design, configuration, diagnostics.
  • Paint Shop Automation — Conveyors, ovens, electrostatic systems, air handling.
  • Electrical Troubleshooting — Strong ability to read schematics and use diagnostic tools.
  • Familiarity with SAP PM, Maximo, or similar maintenance systems.

• Soft Skills
  • Problem Solving under production pressure.
  • Leadership in cross-functional environments.
  • Communication — strong verbal, written, and technical documentation skills.
  • Highly organized, detail-oriented, and self-driven.
  • Passion for automation, innovation, and continuous improvement.

• Preferred Certifications
  • PLC Programming (AB Range).
  • Six Sigma Green Belt / Lean Manufacturing.
  • MES/Traceability Systems.
  • Industrial Cybersecurity.
  • Knowledge of ISO 9001, IATF 16949, ISO 14001, OSHA standards.

Minimum Qualifications:

• Bachelor’s degree in Mechatronics, Electrical Engineering, Mechanical Engineering, or Automation Engineering. Master’s degree or equivalent professional certifications in robotic automation is preferred.
• 6–8 years of hands-on experience with industrial robots in an automotive paint shop or OEM/Tier 1 environment.
• Proven track record in commissioning and sustaining high-throughput paint automation systems.
• Direct experience with major automation platforms (Siemens, AB, Beckhoff, ABB, Fanuc, KUKA, Dürr).
• Electrical safety certifications (NFPA 70E, OSHA) preferred.

Compensation & Benefits:
A comprehensive and competitive benefits package including medical, dental, and vision insurance; life and disability coverage; paid time off; paid holidays; paid sick leave; and a 401(k) retirement plan. Hourly/non-exempt employees accrue up to 120 hours paid time off, and salaried/exempt employees accrue up to 160 hours paid time off. Eligible employees may also participate in an equity program and/or a discretionary annual cash incentive program. Incentive and equity awards, if applicable, are determined based on individual performance, role scope, market considerations, and overall company results, in accordance with the terms of the applicable plans.

Equal Opportunity:
We believe diversity strengthens everything we build. We are proud to be an equal opportunity employer and are committed to providing an inclusive workplace for all. We consider all qualified applicants without regard to race, color, national or ethnic origin, age, religion, disability, sexual orientation, gender, gender identity or expression, marital status, or any other characteristic protected by applicable state or federal laws and regulations.

Accessibility:
We are committed to providing reasonable accommodations for qualified individuals with disabilities. If you need any accommodation to participate in the application process, please contact us at TA-Operations <@> the company.com. This email address is designated solely for accommodation requests and is not monitored for job applications or resume submissions. To be considered for employment, all applications must be submitted through the Careers website.

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To All Recruitment Agencies:
We do not accept agency resumes. Please do not forward resumes; we are not responsible for any fees related to unsolicited resumes.