The Automation Integrator is responsible for designing, programming, integrating, troubleshooting, and continuously improving industrial automation and control systems throughout the Metals manufacturing facilities. This position supports automated production equipment, robotics, PLC-controlled machinery, servo systems, variable frequency drives, machine vision, and manufacturing software integrations.
The ideal candidate combines strong controls-engineering expertise with practical manufacturing experience and can lead automation projects from concept and system design through programming, commissioning, training, and long-term support. This individual will work closely with Engineering, Maintenance, Operations, Quality, IT, equipment manufacturers, and external integrators to improve safety, equipment reliability, productivity, quality, and overall plant performance.
Automation Integrator Essential Functions- Design, program, configure, and troubleshoot programmable logic controllers (PLCs), human-machine interfaces (HMIs), industrial computers, and machine-control systems.
- Develop, modify, and maintain PLC programs using ladder logic, structured text, function block diagrams, and other applicable programming languages.
- Integrate automation equipment with robotics, machine vision, sensors, safety devices, data-acquisition systems, and plant software platforms.
- Program and optimize robotic systems for applications such as material handling, machine tending, assembly, inspection, packaging, and palletizing.
- Configure, commission, and troubleshoot servo motors, servo drives, variable frequency drives (VFDs), encoders, motion-control systems, and industrial communication networks.
- Develop control-system architecture, electrical schematics, panel layouts, I/O lists, sequences of operation, and functional design specifications.
- Ensure automation systems comply with applicable electrical, machinery-safety, and controls-engineering standards.
System Integration and Software Connectivity- Integrate production equipment with manufacturing software, including MES, ERP, SCADA, historian, quality-management, and maintenance-management systems.
- Establish reliable communication between PLCs, robots, databases, industrial computers, and business applications.
- Configure and support industrial communication protocols and networks such as Ethernet/IP, Profinet, Modbus TCP, OPC UA, DeviceNet, and other applicable platforms.
- Develop automated data collection and reporting capabilities for production output, cycle time, downtime, scrap, quality, and equipment performance.
- Collaborate with IT and cybersecurity teams to ensure secure connectivity, user-access controls, backups, and system recovery procedures.
Project Execution and Equipment Commissioning- Lead automation projects from initial concept through design, programming, installation, validation, and production launch.
- Develop project scopes, technical requirements, schedules, budgets, risk assessments, and commissioning plans.
- Review technical proposals and control-system designs submitted by equipment manufacturers and third-party integrators.
- Participate in factory acceptance testing, site acceptance testing, equipment runoff, and final commissioning.
- Verify that new equipment meets established requirements for safety, quality, cycle time, reliability, maintainability, and production capacity.
- Manage contractors and external integrators while maintaining ownership of technical standards and project deliverables.
- Provide advanced technical support for automation-related equipment failures and production interruptions.
- Use structured problem-solving methods to identify root causes and implement permanent corrective actions.
- Improve equipment uptime, cycle time, first-pass yield, changeover performance, and overall equipment effectiveness.
- Identify opportunities to automate manual or repetitive processes while maintaining appropriate safety and quality controls.
- Partner with Operations and Maintenance to reduce recurring downtime and improve equipment reliability.
- Establish preventive and predictive maintenance requirements for automation and control systems.
Documentation and Training- Maintain accurate backups of PLC, HMI, robot, drive, vision-system, and other control programs.
- Develop and maintain electrical drawings, network diagrams, control narratives, equipment manuals, and troubleshooting guides.
- Implement formal change-management and revision-control processes for automation programs.
- Train maintenance technicians, engineers, supervisors, and operators on automation systems, equipment operation, and troubleshooting.
- Support the development of plantwide automation standards and approved equipment specifications.
Required Qualifications- Bachelor's degree in electrical engineering, Controls Engineering, Automation Engineering, Mechatronics, Robotics, or a related technical discipline. An associate degree combined with substantial relevant experience may be considered.
- Minimum of five years of experience programming, integrating, commissioning, and troubleshooting industrial automation systems within a manufacturing environment.
- Demonstrated proficiency in PLC and HMI programming.
- Hands-on experience with industrial robotics and automated manufacturing equipment.
- Strong knowledge of servo motors, servo drives, variable frequency drives, motion control, sensors, instrumentation, and industrial control panels.
- Experience interpreting and developing electrical schematics, wiring diagrams, P&IDs, and control-system documentation.
- Working knowledge of industrial networking, machine communications, and data integration.
- Experience troubleshooting electrical, mechanical, software, networking, and control-system issues.
- Ability to independently manage automation projects from concept through production launch.
Performance ExpectationsSuccess in this position will be measured through:
- Improved equipment uptime and overall equipment effectiveness
- Reduction in automation-related downtime and recurring failures
- Successful completion of automation projects on schedule and within budget
- Increased manufacturing productivity and process capability
- Improved system documentation, program backups, and controls standardization
- Effective integration of automation equipment with plant software systems
- Measurable improvements in safety, quality, labor efficiency, and production performance
- Development of plant personnel's automation and troubleshooting capabilities
Automation Integrator Physical Demands and Work Environment- The noise level in the work environment is usually moderate.
- The employee is exposed to moving mechanical parts.
- Ability to work in an active manufacturing environment and comply with all required safety procedures.
- Ability to access machinery, electrical enclosures, control panels, and production equipment for troubleshooting and commissioning.
- Ability to occasionally lift up to 40 pounds and perform work that may require standing, walking, bending, climbing, or working in confined equipment areas.
- Willingness to provide occasional after-hours, weekend, or emergency technical support during equipment failures, installations, and production launches.
- Limited travel may be required to equipment suppliers, customer locations, or other manufacturing facilities.
Benefits - 401(k) with matching program.
- Medical Insurance
- Dental Insurance
- Vision Insurance
- Short Term Disability
- Long Term Disability
- Life Insurance
- Paid Time Off
- 9 Paid Holidays
Thunderbird is a drug and smoke free work environment and promotes safe work conditions. Pay Range: $100,000 - $115,000 per year
