Sr Automation & Controls Engineer

About The Role

The Sr Staff Automation & Controls Engineer will be at the forefront of designing and implementing advanced automation solutions that drive efficiency, scalability, and quality in our server manufacturing operations. This role requires a strong foundation in mechatronics engineering, combining mechanical, electrical, and software systems to develop integrated automation solutions. They will leverage mechatronics principles to enhance system performance, reliability, and scalability while collaborating across disciplines to support rapid deployment and continuous improvement.

• Contribute to transformation initiatives, helping set new standards for how ZT approaches manufacturing risk analysis, quality, and continuous improvement.
• Define and implement new systems, processes, or frameworks that support the smart factory vision, including automation, metrology, advanced inspection and testing, and predictive analytics.
• Support NPI (New Product Introduction) by developing scalable automation strategies aligned with product roadmaps.
• Design and implement automated assembly and test equipment for server components, including PCBs, power modules, and cooling systems.
• Collaborate with cross-functional teams to ensure Design for Manufacturability (DFM) and Design for Automation (DFA) Principles are embedded in new product designs.
• Translate DFM and PFMEA outputs into actionable process controls, ensuring proactive prevention of variation rather than reactive correction.
• Develop and optimize mechatronic systems integrating robotics, sensors, actuators, PLCs, vision systems, motion control and software.
• Leverage deep, data-rich environments and tools to generate insights and drive continuous improvement initiatives focused on yield, reliability, cycle time, and throughput.
• Work with equipment vendors to specify, validate, and install automation solutions for medium to high-volume production.
• Apply manufacturing techniques such as precision fastening, soldering, adhesive bonding, and vision‑based inspection.
• Lead tool qualification, process documentation, and operator training for new equipment.
• Use data‑driven methods (e.g., SPC, FMEA, DOE) to troubleshoot and enhance manufacturing performance.
• Analyze production workflows to identify automation opportunities and optimize cycle times, throughput, and reliability of automated systems.
• Implement automated inspection and testing systems to ensure product quality.
• Maintain compliance with safety, environmental, and industry standards.
• Create detailed documentation for automated systems, including SOPs and training materials. Provide technical support and training to production teams.

• Bachelor's degree in Engineering, Computer Science, Data Science, or a related field.
• 8+ years of experience in high-volume, high-complexity manufacturing.
• Demonstrated expertise in statistical and analytical methods such as regression analysis, correlation analysis, DOE, SPC, PFMEA, Gauge R&R, and commonality studies.
• Proficiency with data-driven tools such as Minitab, JMP, Python, R, SQL (or equivalent) to analyze and interpret large, complex datasets.
• Track record of driving measurable improvements in yield, reliability, or process robustness.
• Excellent communication skills with the ability to engage at both executive and technical levels.
• Background in electronics assembly, PCBA, servers, or other high-reliability industries (e.g., aerospace, medical devices, automotive, etc.).
• Experience coaching or mentoring technical teams to upskill in data-driven decision-making.
• Proficiency in CAD tools (Solid Works, AutoCAD) and industrial automation platforms (Siemens, Allen-Bradley, etc.).
• Experience with PLC programming, robotic integration (e.g., 6-axis arms, gantry systems), and industrial sensors.
• Familiarity with MES systems, Python, or SQL for automation control.

• Exposure to or knowledge of AI/ML toolsets for statistical problem solving, predictive analytics, or anomaly detection.
• MBA or exposure to business, finance or economics is advantageous.

ZT Systems assesses market data to ensure a competitive compensation package is created for all our employees. The typical base salary for this position is expected to be around $116,250 - $155,000. If hired, the final base salary will be determined on an individual basis taking into consideration experience, skills, knowledge, education and/or certifications.

Base salary is just one component of ZT Systems total rewards philosophy. We take pride in offering a wide range of benefits and perks that appeal to the variety of needs across our diverse employee base. Other rewards may include bonus, paid time off, generous 401k match, tuition reimbursement, wellbeing resources, and more.

• Competitive base salary
• Performance-based annual bonus eligibility
• 401(k) retirement savings plan
• Tuition reimbursement for eligible education programs

• Comprehensive medical, dental, and vision…