Job Summary
The Senior Factory Automation (FA) Engineer provides technical leadership in the design, integration, commissioning, troubleshooting, and optimization of automated manufacturing equipment and robotic systems. This position is responsible for ensuring automation systems operate safely, reliably, and efficiently while meeting production, quality, throughput, and cycle-time requirements.
Responsibilities
- Lead the design, integration, installation, commissioning, qualification, startup, and optimization of automated manufacturing equipment and robotic systems.
- Provide technical leadership for PLCs, industrial robots, motion control, HMIs, sensors, vision systems, industrial networks, and machine safety systems.
- Develop, modify, review, and troubleshoot PLC programs, ladder logic, robot programs, sequence controls, and automation parameters.
- Lead complex troubleshooting and root-cause analysis and implement corrective and preventive actions to reduce downtime and recurring equipment failures.
- Optimize automation systems to improve safety, quality, cycle time, throughput, reliability, and Overall Equipment Effectiveness (OEE).
- Lead automation upgrades, equipment modifications, line expansions, continuous improvement projects, and automation standardization initiatives.
- Define automation requirements and review equipment specifications, control architectures, electrical schematics, sequence diagrams, and control logic.
- Analyze equipment and production data to identify opportunities for improving equipment performance, reliability, and manufacturing efficiency.
- Provide technical guidance, training, and mentorship while collaborating with Production, Process Technology, Quality, Equipment Engineering, Maintenance, EHS, and other cross-functional teams.
Qualifications
- Bachelor's degree in Electrical, Mechanical, Robotics, Automation/Controls, Mechatronics, Manufacturing Engineering, or a related engineering field.
- 7+ years of experience in factory automation, controls engineering, robotics, manufacturing engineering, or a related industrial environment.
- Strong hands-on experience with automated manufacturing equipment and industrial control systems.
- Demonstrated experience with PLC programming, troubleshooting, system integration, and controls development.
- Experience with PLC platforms such as Allen-Bradley/Rockwell, Mitsubishi, Siemens, or equivalent.
- Experience with industrial robots such as FANUC, Nachi, ABB, or equivalent.
- Strong knowledge of automation components and systems, including sensors, actuators, motors, VFDs, servos, motion control, machine safety, and industrial communications.
- Ability to read and interpret electrical schematics, mechanical drawings, ladder logic, sequence diagrams, control architectures, and equipment specifications.
- Demonstrated ability to lead complex technical projects, troubleshoot issues, perform root-cause analysis, and implement sustainable solutions.
- Strong communication, project management, analytical, and problem-solving skills, with the ability to work effectively in a fast-paced manufacturing environment and support installation, commissioning, startup, and production ramp-up activities.
Preferred Skills
- Advanced PLC programming and troubleshooting experience.
- Advanced industrial robot programming, teaching, calibration, and troubleshooting experience.
- Experience with HMI/SCADA, VFDs, servo systems, motion control, machine vision, and automated inspection systems.
- Experience with industrial communication networks, MES, equipment data collection, or digital manufacturing systems.
- Experience with safety PLCs, light curtains, safety scanners, interlocks, emergency-stop systems, and machine safeguarding.
- Experience with CAD tools and automation design or simulation software.
- Proficiency with Microsoft Excel, PowerPoint, and Word.
- Experience with equipment performance monitoring, data analysis, OEE, cycle-time, throughput, and reliability improvement.
- Experience in battery, automotive, electronics, or other high-volume automated manufacturing environments.
- Experience leading automation projects from equipment design through commissioning, qualification, and production release.
