Lead Automation Engineer

Job Description SummaryThe Lead Automation Engineer is responsible for industrializing and sustaining automation and robotic solutions to improve process repeatability, quality, and productivity across the repair facility. This role provides technical leadership in deploying industrial robots, collaborative robots (cobots), and other automation methods to enable consistent and reliable repair processes. The engineer will collaborate with AMRT (Advanced Manufacturing & Repair Technology) and cross-functional teams to standardize applied methods, drive scalability across processes, and build a sustainment program for long-term reliability of automated systems.

Job Description

Roles and Responsibilities

• Define automation architecture, standards, and best practices across PLCs, robotics, motion control, safety, and networking.

• Lead design, programming, and commissioning of industrial and collaborative robots (ABB, Fanuc, UR, KUKA) including integration with vision systems, drives, and HMIs.

• Translate business and process needs into control strategies, functional design specifications, and acceptance criteria.

• Lead automation projects from concept to handover—scope, schedule, budget, risk management, and resource coordination.

• Manage vendors, system integrators, and contractors through FAT/SAT planning, execution, and on-time handover.

• Use offline programming and simulation tools (e.g., ABB RobotStudio, FANUC ROBOGUIDE) for cell design and cycle-time optimization.

• Design, program, and commission Beckhoff TwinCAT 3 systems (IEC 61131-3 ladder, structured text, function block), including motion, EtherCAT I/O, and TwinSAFE.

• Conduct system validation and qualification (IQ/OQ/PQ) and ensure documentation accuracy.

• Implement process control plans, PFMEA, and risk assessments for new automated systems.

• Monitor automation performance using key metrics (OEE, FPY, downtime) and drive root cause analysis and corrective actions.

• Develop sustainment programs for preventive maintenance, software version control, and operator competency.

• Partner with EHS, Quality, Maintenance, and IT to ensure system safety, cybersecurity, and compliance with Life Saving Rules.

• Mentor engineers and technicians in automation and robotics best practices.

• Support continuous improvement and Lean initiatives to enhance flow, safety, and process stability.

Required Qualifications

• Bachelor’s degree in Mechatronics, Controls, Electrical, Mechanical, or Automation Engineering.
• Minimum 5+ years of experience delivering industrial automation and robotics projects from concept to commissioning.
• Proven hands-on experience with industrial robot programming (ABB, Fanuc, UR, or KUKA).
• Strong knowledge of PLCs and control systems, preferably Beckhoff TwinCAT 3 (EtherCAT, motion, TwinSAFE).
• Demonstrated ability to manage automation projects, vendors, and FAT/SAT activities.
• Experience in process industrialization, qualification, and validation (IQ/OQ/PQ).
• Experience integrating vision systems, motion control, and safety interlocks.
• Familiarity with programming languages (Python, C++, or Java) for data interfaces or simulation.
• Knowledge of CAD software (SolidWorks, Siemens NX) for tooling and layout design.

Desired Characteristics

• Strong problem-solving and system integration skills.
• Excellent project management and communication abilities.
• Ability to work cross-functionally and drive initiatives to completion.
• Commitment to safety, quality, and continuous improvement.

Additional Information