This role acts as the key technical link between maintenance and production floor staff, providing direct support to Process Coaches, technicians, and Skilled Trades/Automation personnel. The engineer will ensure operational continuity, maximize equipment efficiency, implement automation and process improvement projects, resolve failures through root cause analysis methodologies, and coordinate area safety strategies.
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Serve as the primary technical point of contact on the floor (Gemba), supporting Process Coaches during process deviations or equipment failures.
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Respond to unplanned downtime/Andon events, restoring operations under strict safety and quality standards.
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Coordinate and follow up on technical/maintenance staff activities (Skilled Trades: Automation) assigned to the area.
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Monitor, diagnose, and reprogram automated control systems (PLCs, servo motors, VFDs, HMI/PanelView).
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Support and adjust automated equipment, HVAC, chillers, pumps, and drives.
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Maintain updated, backed-up control programs and electrical/pneumatic/hydraulic diagrams under change control.
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Lead structured problem-solving sessions and apply Lean tools to remove bottlenecks and improve equipment availability.
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Participate in FMEA and control plan updates for the area.
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Lead retooling/automation projects from design through commissioning and handoff to production.
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Plan and manage technical resources, critical spare parts, and contractor/vendor support.
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Coordinate with Preventive/Predictive Maintenance teams on planned downtime windows.
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Propose and implement innovation projects to optimize equipment performance.
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Ensure compliance with safety standards, energy lockout, and machine risk assessments.
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Ensure equipment modifications meet corporate quality standards and local technical regulations.
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Coordinate area safety strategies and metrics.
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Floor & Process Coach Support – Primary technical liaison for daily operations and downtime response.
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Automation & Controls Diagnostics – Monitoring, diagnosing, and reprogramming automated control systems.
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Root Cause Analysis & Continuous Improvement – Leading problem-solving and Lean initiatives.
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Project & Resource Management – Leading automation/retooling projects and managing technical resources.
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Safety, Quality & Compliance – Ensuring regulatory compliance and coordinating safety strategy.
Qualifications
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Bachelor's degree in Mechatronics, Electronics, Control & Automation, Electrical, Mechanical Engineering, or related field.
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3+ years of experience in automated manufacturing environments (automotive or high-volume manufacturing preferred).
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Proven experience leading root cause analysis (8Ds, FMEA, DMAIC).
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Full flexibility for rotating shifts, weekends, and emergency operational support.
Must Have Skills
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PLC programming and troubleshooting (RSLogix 5000 / Studio 5000 / TIA Portal).
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Industrial network knowledge (EtherNet/IP, Profinet, DeviceNet, remote I/O).
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Advanced reading/interpretation of electrical, pneumatic, and hydraulic diagrams (AutoCAD/ePlan).
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Proven root cause problem-solving leadership (8Ds, FMEA, DMAIC).
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Full availability for shift rotation, weekends, and emergency response.
Highly Desirable Skills
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Experience coordinating with Process Coaches and technical/unionized crews.
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Industrial integration and automation knowledge.
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Familiarity with plant floor monitoring systems (FIS, VisPlant, MES/SCADA).
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Industry 4.0 experience (IIoT, data acquisition, advanced machine vision).
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Lean Six Sigma certification (Green/Black Belt) or Kaizen methodology.
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Intermediate-advanced English for technical communication with global teams and suppliers.
Education Preference
Bachelor's degree in Mechatronics, Electronics, Control & Automation, Electrical, or Mechanical Engineering (or related field).
Competency or Skills to be Gained
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Technical Leadership & Teamwork – Influencing and guiding technicians and operators toward shared goals.
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Sense of Urgency & Resilience – Fast, effective decision-making under pressure during line contingencies.
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Assertive Communication – Translating complex technical requirements into clear operational language.
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Prioritization & Organization – Balancing daily operations with medium/long-term project execution.
