Operations Automation Engineer

Operations Automation Engineer – Job Description

We are seeking a hands‑on Operations Automation Engineer to design, program, support, and continuously improve our custom‑built automated manufacturing and test equipment. This role will focus on standardizing and upgrading our controls platforms (PLC, HMI, motion control, robotics), ensuring reliable performance across multiple production cells. The engineer will work closely with manufacturing engineers, test engineers, and operations teams to maintain and enhance our custom automation solutions that are critical to throughput, quality, and safety.

• Daily on‑site support for automation equipment in one of the highest volume factories at Fluke.
• Provide troubleshooting, root‑cause analysis, and upgrade complex controls/motion/robotics and mechanical issues to support factory operations (OTD & Productivity).
• Maintain and update electrical schematics, controls documentation, and system drawings.
• Integrate vision, sensors, and serial communications into automation equipment.
• Ensure safe operation of all automation equipment in compliance with OSHA and company standards.
• Create, implement, and execute preventative maintenance plans on new and existing equipment.

• Develop, program, and maintain PLC logic, primarily on Automation Direct platforms:
  • Direct Logic and DoMore CPUs
  • Standardize and optimize control logic for consistency and reliability.
• Program, configure, and troubleshoot Automation Direct C‑More HMIs (EA7, EA9, CM5 generations).

• Configure and support Intelligent Actuator (IAI) linear slides:
  • RCP (external controller, I/O PLC control)
  • ERC3 (built-in controller, I/O PLC control)
  • Robonet (external controller, RS485 PLC communication)
• Maintain and improve THK linear slides with stepper motor control driven directly by PLCs.
• Support SCARA robots for contact placement and assembly:
  • Maintain IAI SCARA systems (standalone controller, PLC‑triggered).
  • Program, integrate, and troubleshoot newer Epson SCARA robots with vision systems, including I/O and serial communication with PLCs.

• Partner with manufacturing and test engineers to identify automation upgrades and opportunities to improve cycle time, throughput, and repeatability.
• Lead standardization efforts to consolidate controls platforms across cells.
• Support Kaizen and continuous improvement events with automation expertise.
• Monitor and improve Overall Equipment Effectiveness (OEE), focusing on machine uptime, sustainment, and long‑term reliability of automated systems.

• Lead automation upgrade projects from concept through deployment (requirements, design, programming, debug, validation, training).
• Manage timelines, budgets, and vendors for controls‑related projects.
• Train technicians and engineers in operation and troubleshooting of upgraded equipment.
• Plan, justify, and execute capital equipment (CAPEX) projects, ensuring alignment with operational and financial goals.
• Support implementation and utilization of the CMMS (eMaint) system to track equipment performance, preventive maintenance, and downtime.
• Oversee inventory and spare parts management for automation and controls equipment to minimize downtime and ensure readiness.

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Controls Engineering, Mechatronics, or related field (or equivalent practical experience).
• Hands‑on experience programming and troubleshooting Automation Direct PLCs (Direct Logic, DoMore) and C‑More HMIs.
• Strong background with robotics (IAI robotic slides and SCARA robots).
• Knowledge of industrial communication protocols: I/O, RS485, serial communication, Ethernet/IP.
• Proficiency in troubleshooting and maintaining electromechanical systems in a production environment.
• Excellent cross‑functional collaboration and problem‑solving skills.

• Experience upgrading legacy controls systems and migrating platforms.
• Familiarity with stepper motor control, servo systems, and vision integration.
• Exposure to scripting/programming languages (Python, C#, VB) for automation support.
• Experience with…