Automation Technician

Purpose

Provide advanced technical support for automated manufacturing equipment, robotics, PLC and HMI controls, industrial networks, machine vision, safety systems, electrical controls, and related production processes. The Automation Technician III independently diagnoses complex equipment faults, restores safe operation, supports continuous improvement, and mentors less-experienced technicians.

Assigned Systems and Technologies

·    Industrial robots: FANUC, Motoman and comparable platforms

·    PLCs and software: RSLogix 500, RSLogix 5000, Studio 5000, and RSLinx Classic

·    HMIs, remote I/O, Ethernet, DeviceNet, I/O cards, I/O blocks, and industrial switches

·    Servo and variable-frequency drives, motors, contactors, relays, power supplies, fuses, and circuit breakers

·    Machine-vision cameras, scanners, printers, light curtains, safety devices, and proximity/limit sensors

·    Automated welding equipment, wire feeders, weld torches, reamers, fixtures, and related process equipment

·    WeldWatcher weld-monitoring systems, including approved setup, reference management, limits, alarm review, validation checks, and parameter backup.

·    Automated cells, transfer systems, material handling, and other plant automation as assigned

Essential Duties and Responsibilities

·    Provide daily automation and controls support to production and respond to equipment downtime using safe, structured troubleshooting and documented recovery methods.

·    Connect to PLCs, locate I/O, upload and back up programs, review interlocks, cross-reference tags, and isolate the source of machine faults.

·    Troubleshoot HMIs, sensors, solenoids, relays, contactors, power supplies, I/O cards and blocks, Ethernet switches, industrial networks, scanners, cameras, printers, light curtains, drives, and associated wiring.

·    Perform authorized low-voltage electrical checks using a multimeter; verify voltage type, grounding, continuity, fuses, circuit breakers, and damaged or loose connections.

·    Read and interpret U.S. and European electrical schematics, relay and sensor diagrams, cable pinouts, mechanical drawings, and OEM technical documentation.

·    Perform robot error recovery, verify home and zero positions, back up programs, copy or protect programs, and make authorized position or sequence adjustments using the teach pendant.

·    Modify approved robot and PLC programs, HMI tags or screens, drive parameters, scanner zones, camera references, and device configurations within training and authorization limits.

·    Troubleshoot automated welding applications, including resistance, GMAW, and projection welding; identify faults involving wire feed, torch condition, gas flow, reamers, fixtures, robot position, and weld parameters.

·    Perform authorized WeldWatcher adjustments, including approved reference updates, monitoring-window changes, alarm-limit adjustments, channel or feature selection, and recipe configuration in accordance with validated process standards and change-control requirements.

·    Validate WeldWatcher performance after adjustment by confirming the correct part/program selection, reviewing weld signatures and alarms, completing required challenge or verification checks, and documenting results before returning equipment to production.

·    Troubleshoot WeldWatcher hardware, sensors, communication connections, data acquisition, signal quality, recipe selection, and interface conditions; escalate weld-process or quality decisions to Welding Engineering and Quality as required.

·    Back up and restore approved WeldWatcher configurations, weld references, limits, recipes, and validation records, and maintain traceable documentation of each authorized change.

·    Support communication and network troubleshooting for Remote I/O, Ethernet, DeviceNet, and comparable industrial protocols.

·    Install and replace approved controls hardware, sensors, cables, enclosures, conduit, I/O devices, cameras, scanners, light curtains, drives, and related components.

·    Complete preventive maintenance for automation, robotic, electrical, and weld-process components; identify recurring failures and recommend PM or spare-parts improvements.

·    Support equipment installation, commissioning, run-at-rate, program backup, controls documentation, and acceptance of new or rebuilt automated equipment.

·    Complete work orders, downtime notes, fault findings, program and parameter backup records, parts usage, and shift handoff accurately.

·    Coordinate recovery activities with Production, Maintenance, Quality, Tooling, Engineering, IT/OT, and service providers to protect safety, quality, and delivery.

·    Follow lockout/tagout, electrical safe-work practices, machine guarding, arc-flash requirements, stored-energy control, and approved cell-entry procedures.

·    Train operators and less-experienced technicians on basic error recovery, fault recognition, inspection checks, program backup, and standard troubleshooting methods.

·    Perform other duties as assigned.

Qualifications

Required Education and Experience

·    High school diploma or equivalent.

·    Formal training in industrial automation, electrical technology, mechatronics, robotics, controls, industrial maintenance, or a related technical field; Journeyman or equivalent certification is preferred.

·    Five or more years of industrial automation, controls, robotic, or electrical troubleshooting experience, or an equivalent combination of education and experience.

·    Demonstrated experience with PLC/HMI diagnostics, industrial networks, robots, sensors, drives, safety devices, and low-voltage electrical systems in a production environment.

·    Experience with automated welding or comparable robotic manufacturing processes is strongly preferred.

·    Ability to work assigned shift, overtime, weekends, and emergency call-in coverage as required.

Automation and Controls Competencies

·    Advanced fault isolation across PLC logic, I/O, HMI, networks, sensors, safety circuits, robotics, drives, tooling, and process conditions.

·    Ability to connect to RSLogix 500, RSLogix 5000, and Studio 5000 systems; locate I/O, review interlocks, use cross-reference tools, and perform authorized uploads or backups.

·    Working knowledge of structured programming techniques, robot instructional commands, program structure, and safe editing practices.

·    Ability to configure or troubleshoot industrial communications, including Ethernet, Remote I/O, and DeviceNet.

·    Ability to identify, specify, replace, and configure controls hardware appropriate to the assigned level and work authorization.

·    Proficiency with multimeters, hand tools, electrical schematics, mechanical prints, and approved diagnostic software.

·    Working knowledge of machine vision, scanner, safety, drive, and network device diagnostics and backup procedures.

·    Working knowledge of WeldWatcher setup and diagnostics, including weld references, monitoring features, limits, recipes, alarm interpretation, validation checks, configuration backup, and controlled adjustment within established process and quality requirements.

·    Computer, math, documentation, and communication skills sufficient for controls backups, maintenance records, parts requests, and cross-functional coordination.

Core Values and Professional Behaviors

·    Trustworthiness and ethics: Build productive working relationships, act honestly, and demonstrate sound judgment.

·    Problem solving: Remain calm under pressure, investigate root causes, identify trends, and select effective corrective actions.

·    Decision making and responsibility: Gather information, evaluate alternatives, make effective decisions, and take ownership of results.

·    Communication and teamwork: Communicate clearly and coordinate effectively across departments and service providers.

·    Leadership and development: Mentor technician trainees and less-experienced technicians through coaching and knowledge sharing.

·    Commercial awareness and results orientation: Prioritize work and use resources efficiently while maintaining focus on safety, quality, delivery, and cost.

Level III Expectations

·    Independently troubleshoot complex, interconnected automation, robotic, electrical, network, process, and mechanical conditions.

·    Perform authorized program edits, device replacement, configuration, parameter adjustment, WeldWatcher reference and limit adjustments, and system recovery with appropriate backup, validation, change documentation, and required approval.

·    Prioritize equipment-recovery work and coordinate technical support across departments and external service providers.

·    Mentor Automation Technician trainees and Level I or II technicians in safe troubleshooting, drawing interpretation, diagnostics, programming fundamentals, and standard recovery methods.

·    Support controls standardization, recurring-failure analysis, preventive-maintenance improvement, spare-parts planning, equipment installation, commissioning, and production readiness.

Supervisory Responsibility

This position has no direct supervisory responsibilities. The technician may provide technical direction, training, and task coordination during troubleshooting, repairs, commissioning, and equipment-recovery activities.

Work Environment

Work is performed primarily on the manufacturing floor around automated machinery, robots, electrical enclosures, welding equipment, moving equipment, noise, oils and lubricants, and varying temperatures. Required personal protective equipment and all plant safety controls must be used.

Physical Demands

The employee is regularly required to use hands and fingers to handle, feel, or operate objects, tools, controls, and computer equipment, and to reach with hands and arms. The employee is frequently required to walk, stand, kneel, crouch, talk, hear, and visually inspect equipment indicators and components. The employee must occasionally lift and/or move up to 40 pounds. Specific vision abilities include close vision, distance vision, color vision, and depth perception.