Automation, PLC/SCADA/Robotics expert

Role Summary

The Automation Engineer will design, develop, deploy, and maintain industrial automation solutions across the plant to improve productivity, quality, safety, and scalability. The role covers PLC programming , SCADA/HMI development , robotics integration , motion control , industrial networking , Factory Automation and data acquisition , ensuring reliable and maintainable systems aligned with SOPs, safety standards, and compliance requirements (ISO/IEC).

Key Responsibilities

1) Design & Development

• Program and configure PLCs (Siemens, Allen-Bradley/Rockwell, Schneider, Mitsubishi, Omron) for process and discrete manufacturing lines.
• Develop SCADA/HMI screens (WinCC, FactoryTalk, Ignition, iFIX, Citect, EcoStruxure) with alarms, trends, and reporting.
• Implement robotic systems (ABB, Fanuc, KUKA, Yaskawa) for pick-and-place, assembly, palletizing, welding, or packaging.
• Build motion control solutions (servo/VFDs, CNC controllers), ensuring precise positioning and speed/torque control.
• Design control panels , IO selection, instrument integration (sensors, actuators), and electrical schematics per IEC/NFPA.

2) Integration & Commissioning

• Integrate PLCs with MES/ERP and databases for production data logging and traceability.
• Configure industrial networks (EtherNet/IP, PROFINET, Modbus TCP/RTU, OPC UA), manage VLANs, and device addressing.
• Conduct FAT/SAT , validation, and signoff with stakeholders; prepare SOPs and training materials.
• Lead on-site commissioning , troubleshooting, and optimization during ramp-up.

3) Reliability, Safety & Compliance

• Implement safety PLCs , interlocks, and SIL/PLrated systems; conduct risk assessments and HAZOPs.
• Ensure compliance with ISO 9001 , ISO 45001 , IEC 611313 , IEC 602041 , and electrical safety standards.
• Establish backup/version control for PLC/SCADA projects; maintain documentation and change logs.

4) Continuous Improvement & Support

• Analyze downtime, bottlenecks, and quality issues; execute root cause analysis (RCA) and corrective actions.
• Drive OEE improvement projects, takt time reduction, and energy optimization via smart automation.
• Support predictive maintenance through sensor data, condition monitoring, and analytics.

5) Stakeholder Collaboration

• Work with Production, Maintenance, QA, and Supply Chain to align automation requirements.
• Coordinate with OEMs/system integrators for upgrades, AMC, and spares.

Required Qualifications & Skills

• Bachelors in Electrical/Electronics/Instrumentation/Mechatronics (Masters preferred for senior roles).
• Strong PLC programming : ladder, FBD, SFC, structured text (IEC 611313).
• SCADA/HMI development with alarms, recipes, trends, audit trails.
• Robotics programming (teach pendant & offline), vision systems (Cognex/Keyence) preferred.
• Drives & motion : VFD, servo tuning, positioning, encoders, safety relays.
• Industrial networks : EtherNet/IP, PROFINET, Modbus, OPC UA; basic IT (IP, subnets, firewalls).
• Electrical design : panel wiring, MCC/PLC cabinets, cable schedules, EPLAN/AutoCAD.
• Data acquisition : historian, SQL basics, dashboards (Power BI/Ignition Perspective preferred).
• Strong troubleshooting , documentation, and communication skills.

Preferred / Good-to-Have

• Experience with MES , digital twins , IIoT gateways , MQTT, and edge devices.
• Familiarity with ISA95 , ISA88 (batch) , and GMP (for regulated industries).
• Experience with pneumatics/hydraulics , lean manufacturing , and Kaizen projects.

Certifications (Nice to Have)

• Siemens TIA Portal / Rockwell FactoryTalk certifications
• Automation vendor training (ABB/Fanuc/KUKA/Yaskawa)
• TV Functional Safety Engineer (FS Eng)
• ISA/IEC standards certifications (ISA95, IEC 611313)