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 Alignment- Reports functionally and operationally to the Maintenance Manager
- Works closely with:
- Maintenance Technicians and PLC Technician
- Production and Engineering teams
- External integrators, OEMs, and service providers
- Supports plant-level CAPEX, reliability, safety, and Lean transformation initiatives
Key Responsibilities Automation, PLC & Control Systems- Design, 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 lines
- Robotic systems
- AGV / EGV and automated material handling systems
5. Lead advanced troubleshooting of automation-related failures to minimize downtime.
6. Maintain version control, backups, and change management for all automation programs.
Robotics & Automation Design- Support 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 & Execution- Support 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 Improvement- Support or lead automation-related CAPEX projects, including:
- Scope definition
- Technical evaluation
- Installation, commissioning, and validation
- Support 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 & Standards- Ensure all automation systems comply with:
- OSHA regulations
- Vesuvius Group standards
- Electrical and machine safety requirements
- Support 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 Transfer- Create and maintain:
- Electrical schematics
- Control narratives
- SOPs and technical documentation
- Ensure 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 & Qualifications- Bachelor'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 & Experience- PLCs: Allen-Bradley, Siemens
- HMI / SCADA development and troubleshooting
- Motor controls, VFDs, servo drives, motion control
- Robotics, AGV/EGV systems, vision systems
- Electrical schematics and control panel design
- CMMS usage for PMs, assets, and documentation
- CAD tools (SolidWorks, AutoCAD Electrical - preferred)
Skills & Behaviors- Strong hands-on, shop-floor orientation
- High ownership for equipment reliability and safety
- Structured problem-solving and analytical mindset
- Ability to work independently and manage multiple priorities
- Strong communication across maintenance, production, and engineering
- Willingness to challenge existing solutions constructively
- Discipline in standards, documentation, and execution
