Role summary
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 the 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.
Responsibilities
- 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
- 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
- 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
- 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
- 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
- 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
Qualifications
- Bachelor's degree in Mechatronics, Electrical Engineering, Mechanical Engineering, or Automation Engineering
- 6–8 years of hands-on experience with industrial robots in an automotive paint shop or OEM/Tier 1 environment
Education
Bachelor's degree in Mechatronics, Electrical Engineering, Mechanical Engineering, or Automation Engineering. Master's degree or equivalent professional certifications in robotic automation is preferred.
Experience
6–8 years of hands-on experience with industrial robots in an automotive paint shop or OEM/Tier 1 environment.
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
- 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