Sr Automation Maintenance Engineer

SUMMARY

The Senior Maintenance Automation Engineer is a technical leader responsible for the advanced upkeep, troubleshooting, optimization, and strategic enhancement of automated systems and machinery in a production or industrial environment. This role drives operational excellence, reliability, and innovation, ensuring all systems meet stringent safety and compliance standards. The Senior Engineer collaborates cross-functionally, mentors junior staff, and leads continuous improvement initiatives to maximize automation performance and business value.

 

Key Responsibilities

1. Advanced System Maintenance and Troubleshooting

• Lead complex diagnostics and root cause analysis for automation systems, including PLCs, SCADA, HMI, robotics, and sensors.
• Oversee and optimize preventive and corrective maintenance programs to minimize downtime and extend equipment life.
• Manage system backups, disaster recovery plans, and version control for control system software.

1. Preventive, Predictive, and Reliability-Centered Maintenance

• Design and implement advanced predictive maintenance strategies using tools such as vibration analysis, thermal imaging, and IoT-based monitoring.
• Analyze maintenance data to identify trends and proactively address reliability risks.

1. Process Optimization, Upgrades, and Innovation

• Lead process improvement projects to enhance efficiency, throughput, and reliability of automation systems.
• Evaluate, recommend, and integrate emerging technologies (e.g., IIoT, machine learning, advanced robotics) to drive operational excellence.
• Manage major system upgrades, migrations, and expansions, including hardware and software integration.

1. Safety, Compliance, and Risk Management

• Ensure all automation systems and maintenance activities comply with regulatory standards (OSHA, IEC, NFPA, etc.).
• Develop and enforce advanced safety protocols, including Lockout/Tagout (LOTO), risk assessments, and incident investigations.
• Champion a culture of safety and continuous improvement across the maintenance team.

1. Documentation, Reporting, and Data Analytics

• Oversee comprehensive documentation of maintenance activities, system modifications, and performance metrics.
• Prepare and present detailed reports on system reliability, downtime analysis, and strategic recommendations to leadership.

1. Leadership, Collaboration, and Training

• Mentor and train junior engineers and maintenance staff in advanced automation technologies and troubleshooting techniques.
• Lead cross-functional teams in resolving complex automation challenges and implementing best practices.
• Serve as the primary technical liaison with external vendors, integrators, and technology partners.

 

Key Skills and Competencies

• Expertise in PLC Programming & Troubleshooting: Allen-Bradley, Siemens, Schneider, and advanced programming languages (Structured Text, Ladder Logic, Function Block).
• Advanced HMI/SCADA Systems: Design, integration, and optimization; industrial networking protocols (Ethernet/IP, Modbus, Profinet, OPC UA).
• Robotics & Vision Systems: Deep knowledge of industrial robotics, machine vision, and motion control (VFDs, servos).
• Control Panel Design & Electrical Schematics: Advanced design, commissioning, and troubleshooting.
• Data Analytics: Ability to analyze maintenance and operational data for strategic decision-making.
• Project Management: Proven experience leading automation projects from concept to completion.
• Strong Leadership & Communication: Ability to influence, mentor, and collaborate across all levels of the organization.
• Continuous Improvement Mindset: Lean, Six Sigma, or similar methodologies preferred.

 

Qualifications

• Education: Bachelor’s degree in Automation Engineering, Electrical Engineering, Mechatronics, or related field preferred.
• Experience: Minimum 5+ years in automation maintenance or engineering within an industrial/manufacturing environment, with demonstrated leadership and project management experience.
• Certifications (Preferred): Siemens TIA Portal, Rockwell Automation, ISA/IEC 62443 Cybersecurity, PMP, Lean/Six Sigma, or equivalent.
• Additional: Experience wi