PLC & Automation Engineer - BIW & Paint Shop

Projects

• Validate RFQ - Coordinate for Installation & Commissioning of automation systems in Paint/BIW projects
• Solution development & validation in discussion with suppliers to secure Project deliverables
• Coordinate with vendors , Project , Safety & Maintenance team during project phase
• Ensure equipment installation, commissioning & prove out as per the standard in brown field project
• Provide feedback during engineering phase of the project to vendors and ensure necessary controls are in place for Safety, Quality, Delivery, Cost, Environment, People(SQDCEP) of the process

PLC & Automation System Management

• Handle operation, maintenance, and troubleshooting of PLCs, HMIs, SCADA, and field communication networks (PROFIBUS, PROFINET, Ethernet/IP).
• Maintain and modify logic for PLC's (Siemens S7-300/400/1200/1500, Allen Bradley ControlLogix, or Mitsubishi PLCs etc)
• Develop, modify, and validate interlocks, safety logics, and process control sequences for both BIW and Paint Shop.
• Perform program backups, documentation, and version control as per plant standards.
• Interface PLCs with robots, drives, and higher-level control systems (MES, SCADA).
• Interface with IT as a key user & train other users

Robotics & Mechatronic Systems

• Maintain and troubleshoot industrial robots in BIW (spot welding, MIG welding, material handling) and Paint Shop (painting, sealing, and sanding robots).
• Work with robot controllers for programming and calibration (Fanuc, ABB, KUKA, or Yaskawa etc.)
• Monitor robot paths, process parameters, and communication with PLCs.
• Support robot re-teaching, parameter tuning, and error recovery for cycle optimization.

BIW (Body-in-White) Systems

• Maintain automation systems in spot welding, framing, and sealer application lines etc.
• Troubleshoot electrical and control systems for welding controllers (Aro, Bosch, Medar, OBARA etc), servo guns, and motion controllers.
• Monitor conveyor control systems, lifters, turntables, and positioning devices.
• Ensure accuracy of interlocks, sensors, limit switches, and field I/O modules.
• Implement process improvements to reduce weld cycle time and enhance equipment reliability.

Paint Shop Systems

• Maintain PLCs, HMIs, and automation for :

• • Pretreatment (PT) & Electrodeposition (ED)
• Paint booths, ovens, and circulation systems
• Conveyors and air handling units (AHUs)

• Robotic painting and sealing systems

• Monitor and control temperature, pressure, humidity, and flow through instrumentation systems.

• Support energy optimization in paint booths, curing ovens, and exhaust fans.

Control Panel & Electrical Maintenance

• Maintain and troubleshoot MCCs, control panels, and field junction boxes.
• Perform load analysis, insulation resistance checks, and earth resistance testing.
• Maintain and test safety relays, interlocks, and E-stops as per EHS standards.
• Ensure compliance with IEC, IS, and EHS safety standards.

Data Monitoring & Continuous Improvement

• Utilize SCADA, MES, and data acquisition systems for monitoring downtime and process parameters.
• Perform Root Cause Analysis (RCA) for recurring automation faults and implement corrective actions.
• Support TPM, Kaizen, and Lean initiatives to improve equipment reliability and reduce energy consumption.
• Develop dashboards for cycle time monitoring, robot downtime, and alarm history analysis.

Documentation & Audit Compliance

• Maintain updated electrical schematics, control logic diagrams, and automation documentation.
• Keep preventive maintenance and calibration records for all automation systems.
• Ensure compliance with IATF 16949, ISO 14001, and ISO 45001 requirements.
• Participate in internal and external audits (EHS, TPM, IATF) with relevant data and reports.