Sr Automation Maintenance Engineer

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.

• 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.
• 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.
• 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.
• 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.
• 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.
• 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.

• 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.

• 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 with IIoT, Industry 4.0, and digital transformation initiatives is highly desirable.

• Medi…