Senior Automation Engineer, Systems/Applications Design

General Overview

Functional Area:  Engineering        
Career Stream:  Design Engineering Systems Applications
SAP Short Name:  SLE-ENG-DSA
Job Level:  Level 09
IC/MGR:  Individual Contributor        
Direct/Indirect Indicator:  Indirect

Summary

The Automation Systems Engineering role is a highly interdisciplinary technical position that collaborates with cross-functional teams (mechanical engineers, production, and project leadership) to ensure the robust development, integration, and deployment of high-quality automated manufacturing systems.

The senior Automation Engineer designs, programs, and integrates complex automated equipment over its entire lifecycle, from concept and hardware design to final commissioning. Serving as a technical expert, you will be engaged in critical phases such as requirements engineering, PLC logic development (TIA Portal), industrial robotics integration (KUKA, ABB, Mitsubishi), advanced vision systems (Cognex, Keyence, SICK), and motion control (Festo, SMC). You will ensure seamless operation, maintainability, and continuous improvement of automated lines, bridging the gap between shop-floor control and higher-level manufacturing execution systems (MES). You will continuously enhance system designs with feedback from Factory/Site Acceptance Testing (FAT/SAT), manufacturing operations, and reliability reviews.

Detailed Description

Performs tasks such as, but not limited to, the following:

• Automation Architecture & Hardware Design, lead the design, development, and implementation of complex automated control systems. Research and specify electrical components, design control cabinets, and oversee panel building. (Experience with EPLAN for electrical design is a strong advantage).
• Develop, implement, and troubleshoot advanced PLC control logic from scratch, with a strong focus on Siemens TIA Portal.
• Ability to design intuitive, user-friendly operator interfaces and high-level data acquisition systems (Siemens WinCC Unified, Ignition).
• Experience programming Safety PLCs (Siemens F-CPU, Pilz) and configuring advanced robot safety parameters (KUKA SafeOperation, ABB SafeMove).
• Program, teach, and optimize industrial robots (primarily KUKA and ABB, with adaptability to other brands) for precise manufacturing tasks.
• Design and deploy complex machine vision solutions using Cognex, SICK, and Keyence. Applications include 2D/3D robot guidance (part localization) and detailed quality inspection.
• Parametrize variable frequency drives and servo systems. Design and control electrical and pneumatic axes networks (ex. Festo, SMC, Rexroth).
• High-Level System Integration (MES), bridge the gap between shop-floor automation and upper-level IT systems. Integrate PLC data with MES. Programming skills in C# / VB for system integration constitute a significant advantage.
• Test, simulate, and measure equipment performance. Lead Factory/Site Acceptance Testing (FAT/SAT), troubleshoot complex issues, and optimize machine cycle times.
• Provide technical direction to a team of engineers (mechanical, electrical, software). Divide up tasks taking into consideration safety standards, reliability, and maintainability.
• Review, interpret, and negotiate technical specifications with customers. Manage technical relationships with key hardware vendors and partners (Siemens, Kuka, Cognex, etc.).
• Create and maintain comprehensive technical documentation, including electrical schematics, I/O lists, user manuals, and technical reports.
• Proactively promote industry best practices in automation, analyze machine data, and recommend system modifications or retrofits.
• Proficiency with modern Industry 4.0 communication protocols, including OPC UA, MQTT, and IO-Link architectures.
• Experience with offline programming and process simulation prior to physical build, using software such as Siemens NX MCD, ABB RobotStudio, or KUKA.Sim.

Knowledge/Skills/Competencies

Core Technical Knowledge:

• Comprehensive understanding of control theory, machine kinematics, and industrial automation architectures.
• Strong knowledge of international machine safety standards and regulations (e.g., ISO 13849 for machinery safety, ISO 10218 for industrial robots) and electrical design standards.
• Solid understanding of machine vision fundamentals, including lighting techniques, optics, and image processing algorithms for localization and quality inspection.
• Strong grasp of how shop-floor Operational Technology (OT) networks interface with Information Technology (IT) enterprise systems (MES, ERP).

Software & Programming Competencies:

• Expert-level proficiency in IEC 61131-3 programming languages (Ladder, SCL/ST, FBD) within the Siemens TIA Portal ecosystem.
• High-level competency in specific robot programming languages, primarily KUKA (KRL) and ABB (RAPID).
• Solid understanding of object-oriented programming concepts, with practical skills in C# or VB.NET for system integration and data manipulation.
• Ability to read, interpret, and ideally create complex electrical schematics using EPLAN or AutoCAD Electrical.

Professional Competencies & Soft Skills:

• Exceptional analytical skills with the ability to troubleshoot multidisciplinary (electrical, mechanical, software) issues under pressure, especially during commissioning phases.
• Proven ability to lead technical workstreams, mentor junior engineers, and manage tasks across cross-functional teams.
• Excellent verbal and written communication skills to effectively negotiate technical specs with customers, manage vendors, and write clear documentation.
• A high degree of adaptability to learn new hardware platforms and stay current with emerging Industry 4.0 technologies.

Physical Demands

• Duties of this position are performed in a normal office environment.
• Duties may require extended periods of sitting and sustained visual concentration on a computer monitor or on numbers and other detailed data. 
• Repetitive manual movements (e.g., data entry, using a computer mouse, using a calculator, etc.) are frequently required.
• Occasional travel may be required.

Typical Experience

• 4 to 6 years in a similar role or industry.

Typical Education

Bachelor degree or consideration of an equivalent combination of education and experience.

Educational Requirements may vary by Geography

Notes

This job description is not intended to be an exhaustive list of all duties and responsibilities of the position. Employees are held accountable for all duties of the job. Job duties and the % of time identified for any function are subject to change at any time.