Sr. Automation Engineer, Paint

The Sr. Paint Automation Engineer is responsible for the full lifecycle engineering, optimization, and technical oversight of automotive paint processes. This includes managing a skilled team to ensure the implementation of Class A surface finish standards, high first-time quality (FTQ), environmental compliance, and robust process controls across pretreatment, electrocoat, primer, basecoat, and clearcoat stages. The manager interfaces with design, production, quality, maintenance, and external suppliers to deliver a world-class, efficient, and defect-free painted bodies. 

• Design, develop, and implement control strategies for robotic and automation systems in paint booth, sealer, and utility areas
• Develop and modify PLC logic (Siemens S7/TIA Portal, Allen-Bradley, Beckhoff) for paint shop systems such as material conveyors, ovens, elevators, turntables, and skids 
• Configure and program robot paths and paint parameters for systems such as ABB IRB5500, Fanuc R-2000iC, KUKA KR series, or Dürr EcoRP 
• Design and integrate HMI/SCADA interfaces for operator interaction, alarms, diagnostics, and data logging

• Participate in new plant installations, upgrades, and expansions—leading automation commissioning for the paint shop 
• Support Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) for automation hardware and software
• Conduct I/O validation, functional testing, and interlock verifications for safety and process controls
• Optimize line balancing, takt time, and cycle times during the commissioning and ramp-up phase

• Interface with Manufacturing Execution Systems (MES), Quality Management Systems (QMS), and Plant SCADA to enable data capture, recipe control, and traceability 
• Support integration of vision systems for defect detection and robotic path adjustments 
• Deploy and maintain IoT edge devices or OPC-UA/MQTT-based systems for real-time monitoring and diagnostics 

• Continuously analyze process KPIs (e.g., FTQ, uptime, overspray, paint usage, rework rates) and implement automation-based corrective actions
• Improve energy efficiency and resource consumption (compressed air, power, paint, deionized water) through automated optimization
• Implement predictive maintenance algorithms using historical automation data to minimize unplanned downtimes

• Ensure all automation systems comply with local and international safety standards (e.g., CE, ISO 13849, OSHA, NFPA 79) 
• Conduct risk assessments for new automation setups and update safety circuits (e.g., Pilz, Siemens SICK) accordingly
• Implement error-proofing (poka-yoke) features using automation to prevent human error and improve quality
• Support audits and certifications related to paint operations and automation controls 

• Create detailed documentation: electrical and pneumatic schematics (EPLAN preferred), PLC/HMI code backups, FMEA reports, and robot backup routines
• Develop SOPs and training modules for maintenance and production operators on automated systems and troubleshooting
• Establish automation change management logs and version control procedures

• Bachelor's degree in Control Systems Engineering, Electrical & Control Engineering or Automation & Control Engineering 
• Experience: Minimum of 5+ years of automation maintenance experience in an automotive paint shop or similar industrial environment, with at least 3 years in a supervisory roles
• Master’s degree or PMP certification is a plus

• Strong problem-solving ability under production pressure
• Leadership in cross-functional environments
• Clear and professional communication skills, including technical writing
• Highly organized, detail-oriented, and self-motivated
• Passionate about automation, innovation, and continuous improvement