Automation Specialist/Tool and Die Technician

The Automation Specialist/Tool and Die Technician is responsible for maintaining, troubleshooting, repairing, and improving production tooling and automated manufacturing equipment.  The position supports safe, reliable production through die maintenance, tooling improvements, automation support, preventative maintenance, root-cause problem solving, and new equipment and tooling launches.  Work is performed on the production floor and in the tool room, with occasional office-based documentation and planning.

Duties to include but not limited to:

Automation and Equipment Responsibilities

• Troubleshoot and support automated milling, sawing, bending, assembly, material handling, and related manufacturing systems.  
• Diagnose mechanical, electrical, pneumatic, hydraulic, sensor, robot and drive-related equipment issues and coordinate repairs with maintenance and engineering.
• Program, teach, recover and support industrial robots, including Fanuc and ABB systems, when qualified and authorized.
• Identify equipment and tooling weak points and implement cost-effective modifications that improve safety, quality, throughput, reliability, tool life, and maintainability.

Tool and Die Responsibilities

• Troubleshoot, repair, maintain, and improve progressive, transfer, blanking, trim, form, and related production dies and tooling.  
• Perform preventative maintenance, die disassembly and assembly, spotting, fitting, sharpening, polishing, component replacement and adjustment of tooling clearances.
• Diagnose dimensional, cosmetic, and process defects caused by tooling; complete corrective repairs and verify acceptable operation before release to production.
• Support die changeovers, press setup, tool tryouts, first-piece approval activities and production restart following repairs.
• Operate applicable tool-room equipment, including precision hand and power tools
• Use precision measuring instruments and interpret tooling drawings, blueprints, tolerances, and geometric dimensioning and tolerancing requirements.
• Maintain die history, repair documentation, preventative maintenance records, tooling spare parts information and accurate work-order closure.

Launch, Quality and Continuous Improvement

• Participate in new product, tooling, and equipment launches from design review and tryout through installation, validation and production handoff.
• Support tooling capacity and capability verification, PPAP readiness, control-plan requirements, PFEMA actions and corrective-action implementation.
• Apply structured problem-solving methods, such as 5 Why, fishbone analysis, and 8D support, to prevent recurring tooling and equipment failures.
• Analyze downtime, maintenance, scrap, and tooling data to prioritize improvements and reduce waste.
• Participate in Lean Manufacturing, Continuous Improvement, 5S, TPM, preventative maintenance and related plant initiatives.
• Follow applicable quality and environmental management system requirements, customer-specific requirements, and internal procedures.

Training & Leadership

• Train maintenance and production team members on tooling care, equipment setup, basic troubleshooting and safe operating practices.
• Work independently as a self-starter while escalating safety, quality, and production concerns appropriately.

Collaboration & Communication

• Collaborate with production, quality, engineering, suppliers, subcontractors, and tool shops to resolve technical issues.
• Communicate repair status, production risks, containment needs and recommended corrective actions promptly and accurately.
• Work effectively in a multicultural, cross-functional team environment and complete assigned action items on schedule.

Authorization Level:

• Authorized to stop production or equipment operation when an immediate safety risk or tooling-related quality concern is present and notify the appropriate supervisor.

Safety and Compliance:

• Follow all plant safety rules and applicable requirements for lockout/tagout, machine safeguarding, electrical safety, proper PPE, and safe tool-room practices.
• Inspect work areas and equipment for unsafe conditions and promptly report or correct hazards within the employee’s training and authority.
• Ensure repaired or modified equipment is restored with required guards, interlocks, safety devices, and documented verification before return to service.
• Maintain orderly work areas in accordance with 5S and environmental requirements.

Technical Knowledge & Skills
•    Strong knowledge of tool and die construction, robotics, maintenance, repair, troubleshooting and production support.
•    Ability to use precision measuring equipment, including micrometers, calipers, indicators, and related inspection tools.
•    Ability to read and interpret tooling drawings, mechanical and electrical blueprints, schematics, sensors, drives and industrial automation.
•    Knowledge of industrial robot controllers, familiarity with robot programming, teaching recovery and maintenance preferred.
•    Working knowledge of Windows and Microsoft Office, including Teams, 
Excel, Word and PowerPoint.

Experience Requirements
•    3–5 years of experience in an automotive manufacturing or other related manufacturing environment.
•    Hands-on experience with stamping, automated milling, bending, or aluminum manufacturing processes preferred.

Interpersonal & Professional Skills
•    Strong analytical, troubleshooting and problem solving skills.
•    Good verbal and written communication skills and the ability to document completed work accurately.
•    Ability to manage multiple priorities, respond to production needs, and work effectively in a fast-paced environment.
•    Ability to work independently and collaboratively with self-motivation, accountability and proactive engagement.
•    Ability to train maintenance personnel and other team members.

Education
•    Associate degree or technical diploma in Tool and Die Technology, Machine Tool Technology, Mechatronics, Robotics, or related field preferred. 
•    Completion of a recognized tool and die apprenticeship, journeyman certification, or equivalent combination of education and relevant experience is preferred.