Automation Engineer

Position Summary

The Automation Engineer is responsible for the design, programming, implementation, troubleshooting, and continuous improvement of industrial automation systems supporting manufacturing operations. This role will lead controls logic development, machine safety design, robotic programming, vision system integration, and commissioning activities for automated manufacturing equipment.

The position will play a key role in the development, startup, and optimization of a new robotic welding cell with integrated robotic material handling. The successful candidate will serve as the facility's technical expert for Allen-Bradley controls platforms and FANUC robotics while ensuring the highest standards of safety, reliability, and production performance.

Essential Responsibilities

Controls Engineering & Automation

• Design, develop, and maintain PLC programs utilizing the Allen-Bradley / Rockwell Automation platform.
• Develop control logic using Studio 5000 Logix Designer and FactoryTalk software applications.
• Design and maintain HMI interfaces for machine operation, diagnostics, and troubleshooting.
• Configure and support industrial communications including EtherNet/IP and managed industrial networks.
• Troubleshoot and resolve controls-related issues to minimize downtime and improve system performance.
• Support commissioning, startup, and validation of new automated equipment.
• Maintain electrical schematics, PLC backups, controls documentation, and change management records.

Functional Safety & Machine Safety

• Design, program, and validate machine safety systems utilizing Allen-Bradley GuardLogix and safety-rated devices.
• Develop safety logic and safety architectures for robotic welding and material handling cells.
• Conduct machine risk assessments and implement appropriate safeguarding solutions.
• Validate and maintain safety devices including:
• Safety scanners
• Light curtains
• Safety interlock switches
• E-stop circuits
• Area protection systems
• Safety relays
• Ensure compliance with OSHA, ANSI/RIA, NFPA 79, ISO 10218, and ISO 13849 standards.
• Develop and maintain facility machine safety infrastructure and standards.

FANUC Robot Programming & Integration

• Program, configure, and troubleshoot FANUC industrial robots supporting welding and material handling operations.
• Develop robot paths, process logic, and production sequences.
• Optimize robot cycle times, process quality, and equipment reliability.
• Configure robot I/O, communications, and PLC integration.
• Support robot commissioning, production startup, and continuous improvement activities.
• Perform robot recoveries, backups, software management, and preventive maintenance support.
• Support integration of welding equipment, tooling, positioners, conveyors, and ancillary automation systems.

New Equipment & Project Support

• Lead controls and automation activities for equipment installation and startup.
• Assist in the launch of a new robotic welding cell with robotic material handling.
• Coordinate with equipment suppliers, maintenance, and production personnel.
• Participate in equipment design reviews and production qualification activities.
• Participate in developing automation standards and best practices for future equipment installations.

Continuous Improvement

• Identify opportunities to improve safety, quality, productivity, and equipment uptime.
• Support root cause analysis and implementation of corrective actions.
• Train maintenance and operations personnel on robotic and automation systems.
• Support lean manufacturing initiatives and operational excellence programs.

Required Qualifications

• Bachelor's Degree in Electrical Engineering, Mechatronics Engineering, Controls Engineering, or Associate Degree or Technical Certification in Automation, Mechatronics, Electrical Technology, or related field.
• Minimum 3-5 years of experience with industrial automation and controls systems.
• Demonstrated experience with Allen-Bradley PLC programming and automation systems.
• Experience programming and integrating FANUC robots.
• Strong experience with PLCs, robotics, machine safety systems, and industrial electrical controls.
• Must be a "US Person" per ITAR regulations. Per the International Traffic in Arms Regulations (ITAR) (22 CFR § 120.62), a U.S. Person is any individual who is a U.S. citizen, a lawful permanent resident (green card holder), or a "protected individual".

Preferred Qualifications

• Experience supporting robotic automation applications.
• Experience supporting robotic material handling systems.
• Proficiency with:
• Allen-Bradley ControlLogix and CompactLogix PLCs
• Studio 5000
• FactoryTalk View SE/ME
• GuardLogix Safety PLCs
• FANUC Robotics (R-30iB controllers and current platforms)
• FANUC Roboguide software
• Experience with servo motion systems and VFDs.
• Experience integrating welding power supplies and robotic welding processes.
• Experience leading automation projects and equipment launches.

Technical Skills

Required Platforms

• Allen-Bradley / Rockwell Automation
• ControlLogix
• CompactLogix
• GuardLogix
• Studio 5000
• FactoryTalk View

Robotics

• FANUC Robotics
• Robot programming
• Robot integration
• Roboguide
• Arc welding applications
• Material handling applications

Additional Technical Skills

• EtherNet/IP Networks
• Machine Safety Systems
• Risk Assessment
• Servo Motion Control
• Welding Automation
• Industrial Networking
• Electrical Troubleshooting
• Root Cause Analysis
• Project Management

Key Performance Objectives

• Successfully launch and support a new robotic welding cell and robotic material handling system.
• Maintain world-class safety performance through robust machine safety design and compliance.
• Achieve automation uptime and reliability targets.
• Reduce downtime through effective troubleshooting and continuous improvement initiatives.
• Serve as the facility subject matter expert for Allen-Bradley controls and FANUC robotics systems.

American Steel and Aluminum LLC provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability or genetics. In addition to federal law requirements, American Steel and Aluminum LLC complies with applicable state and local laws governing nondiscrimination in employment in every location in which the company has facilities. This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.

American Steel and Aluminum LLC expressly prohibits any form of workplace harassment based on race, color, religion, gender, sexual orientation, gender identity or expression, national origin, age, genetic information, disability, or veteran status. Improper interference with the ability of American Steel and Aluminum LLC’s employees to perform their job duties may result in discipline up to and including discharge.

Pay: $85,000.00 - $98,867.83 per year

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Flexible spending account
• Health insurance
• Health savings account
• Life insurance
• Paid time off
• Parental leave
• Professional development assistance
• Retirement plan
• Tuition reimbursement
• Vision insurance

Work Location: In person

Salary : $85,000 - $98,868