Sr. Automation Engineer, BiW

As a Sr. Automation Engineer, BiW, you will concentrate on controls of PLC driven robotic cells, servo actuated mechatronic systems and high‐volume automated process equipment. The candidate will be responsible for robotic systems planning, wiring and dress packs buyoffs, installation, programming, debug, and commissioning of robotic and PLC equipment systems related to company new vehicle launch and carry over programs in the Prototype and production shops. Candidate will be handling development of Robotics & Controls system architecture, standards, programs, and reviewing integrator's production line robotics / controls design, and handling launch of production line onsite by verifying installation, commissioning & launch of robotic & controls systems for various systems including robotic welding lines for body shop. Candidate will also be involved in developing and performing preventative maintenance and failure recovery strategies for automation systems.

You will:

• Engage with Line builders / integrators, Equipment Suppliers, in developing robotic and controls standards, configurations, & programs and selection of specific equipment and accessories for the required applications
• Manage and track development of BIW automation (Robotics & Controls) manufacturing systems from initial design phase to installation & commissioning to systems sustenance during production
• Interface with equipment suppliers to manage and track procurement of automation equipment
• Participate in reviewing, auditing and buy-off of automation system for production capability and safety
• Architect, write and debug PLC ladder logic with an emphasis on generating code that is organized, structured, documented, maintainable and reusable.
• Develop & integrate aesthetically simple HMI screens for complex BIW Production machinery while providing sufficient feedback for troubleshooting
• Programming, troubleshooting, and preparation of robots to BIW specifications and cell implementation
• Integrate equipment, robotics systems, and other automation equipment (such as conveyors) into an automated line system controlled via PLC
• Teach and operate robots for production on the floor
• Integrate and commission EOAT onto robots, such as Weld Guns, SPR guns, FDS Guns, Material Handler, Vision Cameras, etc.
• Develop I/O Maps for direct communication between Robots and EOAT
• Develop efficient robot teach paths and programs with safe yet efficient robot x robot and equipment interlocks in interference zones
• Perform robot debug and PLC Debug and commissioning activities on shop floor and Vendor site
• Interface with cross functional groups, including MES, Maintenance, Manufacturing Engineering, Production, and Suppliers to ensure production line automation systems are designed to functional spec required by each group
• Develop and implement software designs from functional specifications utilizing Allan Bradley and other software packages
• Prepare software documentation for Buyoff, and final documentation
• Comply with and enforce all company and customer safety policies
• Develop & enforce automation systems standards, safety, programs, and maintenance plans across all BIW manufacturing lines and processes
• Participate in initial equipment conceptual development and carefully balance product specifications, process requirements, layout complexity, cost, and lead‐time limits.
• Manage electrical cabinet builds, field wiring, pneumatic, and fluid/pneumatic plumbing
• Select and size electrical and electromechanical components such as servos
• Debug and optimize automated processes to maximize cycle time, improve availability and yield

You bring:

• Bachelor’s Degree in Electrical, Mechanical, Computer engineering or related field is preferred, a combination of years of experience may be considered in lieu of degree 
• 5+ years of experience as a hands‐on Controls Engineer or Robotics Engineer working on automation and/or electromechanical systems
• Proficiency with process integration and electromechanical / mechatronic systems
• In‐depth knowledge of Equipment and Robot Safety standards (such as ANSI/RIA15.06 [ISO 10218], ANSI B11 [ISO 13849], OSHA, Etc.).
• Must Have advanced proficiency in programming Fanuc Robots and familiar with others (ie: Kuka, Yaskawa)
• Experience programming Cartesian, SCARA and Articulated robots (Fanuc, Kuka, Motoman, ABB, etc)
• Advanced proficiency programming industrial equipment Ladder logic PLCs (Allen Bradley ControlLogix, CompactLogix and RSLogix 5000), Safety PLCs (Allen Bradley ControlLogix, SmartGuard, Omron, Pilz) and Human Machine Interface (HMI / GUI ‐ AB Panel view, FactoryTalk, LabView, Ignition)
• Knowledge and experience of communication protocols / Field bus Networks (IO Link, AB DeviceNet, Ethernet IP, Safety rated field bus networks)
• Serial communication (RS‐232) between PLCs and instruments
• Ethernet communications between machine PLCs and database systems
• Demonstrated excellence in programming PLCs. Must have a well‐defined methodology for maintaining code structure and organization. Ability to program state machines for complex processes which involve multi‐station parallel processing, pick and place automation, data acquisition, and PID control. Proven ability to design fault‐tolerant systems with error handling and recovery
• Proficiency selecting appropriate circuit protectors, wire and cable, sensors, safety hardware, PLC hardware, remote I/O, VFD and servo systems
• Proficiency creating detailed electrical and fluid schematics in CAD (AutoCAD Electrical preferred)
• Proficiency programming and tuning variable frequency drives
• Exposure to a wide variety of production machinery, industrial sensors, and equipment such as Robot systems, joining systems such as RSW Weld Guns, SPR Joining Guns, Adhesive Servo Driven Dispense systems, LVDT and pressure transducers, temperature controllers, DC nutrunner torque controllers, current and power meters, etc)
• Experience with Vision systems (Cognex, Keyence, Fanuc)
• Experience with simulation software’s such as Process Simulate and Roboguide.
• Experience creating technical specifications for automated manufacturing equipment is highly desired
• Experience transitioning products and processes from prototype to production desired
• Knowledge of production quality metrics is a plus
• Ability to use 3D CAD packages such as with SolidWorks and CATIA