Automation - Maintenance Engineer

Chengalpet Taluk, TN, IN, 603002

Objectives of the Position

The Automation Engineer in maintenance team will be responsible for supporting site’s operations by ensuring optimal performance of automation systems at the site. The role requires expertise in PLC systems, robotics, HMIs, VFDs, and industrial automation to minimize downtime, optimize efficiency, and enhance equipment reliability.

Key Responsibilities

• Provide 24x7 shift automation support to ensure smooth plant operations( 3 shift pattern).
• Improve and maintain Operational Stability Factor (OSF), Mean Time Between Failures (MTBF), and Mean Time to Repair (MTTR) for all automation equipment as per KPI.
• Troubleshoot, debug, and resolve automation-related breakdowns to support plant’s operation.
• Possess strong working knowledge of Siemens PLC and robotic automation systems, including:
  • Siemens (S7-300, S7-400, S7-12/1500)
  • Robots (ABB & Kuka)
  • HMI systems (Wonderware InTouch, WinCC, PanelView)
  • Industrial printers (Inkjet, LASER, Label)
  • Scanners and 2D & 3D vision systems (Sick, Keyence, Cognex)
  • VFD & Servo drives (Sinamics, Micro-master, Powerflex)
  • Good knowledge of E-plan or electrical drawing for troubleshooting issues.
• Execute automation improvement projects and implement cost-effective solutions.
• Conduct root cause analysis (RCA) for recurring automation failures and implement Corrective and Preventive Actions (CAPA).
• Participate in Preventive Maintenance (PM) programs and coordinate operational activities with internal teams and vendors.
• Maintain and update technical documentation, like Software validations, Interlock validations, Backup management, RCA reports, and Standard Operating Procedures (SOPs).
• Work within SAP PM for work permit systems, work order closure, and maintenance planning.
• Provide technical insights in change discussions and continuous improvement initiatives.
• Ensure compliance with safety protocols and reinforce a clean and safe working environment through 3C & 5S practices.
• Contribute to achieving Zero Accident targets by identifying and mitigating potential hazards and conducting risk assessments.

Technical Qualifications & Expertise

• Siemens PLC (S7-300, 400, 1500) troubleshooting
• ABB/Kuka Robots (programming and troubleshooting)
• Wonderware InTouch / WINCC / PanelView
• Industrial printers (Ink based, LASER markers, Label printers)
• VFD & Servo drives (Sinamics, Micro-master, Powerflex)
• Scanners and 2D & 3D vision systems (Sick, Keyence, Cognex)
• Electrical wiring diagrams – power and control wiring knowledge
• Hydraulics & Pneumatics Operated Machines
• Hands-on experience with Special Purpose Machines (SPMs)
• Knowledge of problem-solving methods like 5Why, 4D, RCA, FMEA
• Exposure to statutory requirements and compliance in automation
• Ability to work with various global vendors and suppliers for automation systems.

Educational & Professional Qualifications

• Education: B.E / B.Tech. in Automation, Mechatronics, Instrumentation, Electrical & Electronics (EEE), or Electronics & Communication (ECE).
• Experience: Minimum 6 years in Auto Ancillary, Process Industry, or Industrial Automation.
• Industry Exposure: Hands-on experience in PLC-based automation, robotics, and industrial control systems.

Key Competencies & Soft Skills

• Analytical & Troubleshooting Skills – Ability to diagnose and resolve automation issues efficiently.
• Adaptability & Decision-Making – Quick thinking to address breakdowns and ensure minimal downtime.
• Collaboration & Communication – Work effectively with cross-functional teams, vendors, and maintenance staff.
• Safety & Compliance Awareness – Strong focus on risk mitigation and process safety adherence.
• Continuous Improvement Mindset – Proactively contribute to process enhancements and cost optimizations.