Lead Engineer - Industrial Automation and PLC Programming

Ford Motor; Chennai; On-site; INR 1,400,000 - 2,100,000; Full time

Job summary

Ford Motor in Chennai seeks an Industrial Automation and PLC Programming Lead to act as SME for shop-floor automation, overseeing PLC/HMI, MES interfaces, robotics, and connectivity. This role drives programming standards, reusable libraries, and maintainable automation across plants.

The position blends hands-on production support with long-term standardization, leading root-cause analysis and incident tracking while providing technical leadership with IT, OT, and supplier teams to ensure

Qualifications

• Bachelor's degree in Electrical/Automation Engineering or closely related field
• 6–10 years of experience in industrial automation, controls engineering, PLC programming, or manufacturing systems
• Hands-on experience developing, troubleshooting, and maintaining PLC applications
• Experience performing root-cause analysis and implementing permanent corrective actions
• Experience documenting controls standards, technical procedures, or engineering best practices

Responsibilities

• Provide advanced troubleshooting and programming support for PLCs, HMIs, MES interfaces, robotics, and shop-floor systems
• Develop, document, and implement PLC/HMI programming standards and reusable libraries
• Lead technical reviews, design audits, and migration of legacy controls against standards
• Support MES integration, data exchange, and industrial connectivity
• Coordinate with IT, OT, suppliers, and maintenance teams during issue resolution

Skills

PLC programming

HMI development

Root-cause analysis

Structured problem-solving

Technical leadership

Education

Bachelor's degree in Electrical/Automation Engineering

Tools

Allen-Bradley Studio 5000

Siemens TIA Portal

FactoryTalk View

Siemens WinCC

Job description

Industrial Automation and PLC Programming Lead

The Industrial Automation and PLC Programming Lead will serve as a technical subject-matter expert for shop-floor automation and controls systems supporting manufacturing operations and forward model programs. This position combines hands-on production support with long-term technical standardization. The role will manage and prioritize automation-related support requests, troubleshoot production-impacting issues, perform root-cause analysis, and serve as an escalation point for complex or recurring controls problems. The position will also lead the development, documentation, and implementation of programming standards, reusable software libraries, naming conventions, controls templates, and engineering best practices. The role will work closely with manufacturing engineering, information technology, operational technology, equipment suppliers, system integrators, and plant support teams to ensure that automation solutions are reliable, secure, maintainable, and aligned with applicable organizational and Original Equipment Manufacturer standards.

Production and Technical Support

Manage and prioritize technical support requests involving PLCs, HMIs, MES interfaces, robotics, and industrial connectivity systems. Provide advanced troubleshooting and programming support for production-impacting controls and automation issues. Diagnose PLC logic, HMI application, communication, robotics, and shop-floor system failures. Perform structured root-cause analysis and implement sustainable corrective and preventive actions. Act as an escalation point for complex, recurring, or high-impact technical issues. Coordinate with manufacturing, maintenance, controls engineering, information technology, operational technology, and supplier teams during issue resolution. Maintain accurate records of incidents, technical findings, implemented solutions, and lessons learned. Define and monitor appropriate service-level measures and key performance indicators for issue response, resolution, system reliability, and recurring failures.

Controls Standards and Standardization

Develop, document, implement, and maintain PLC and HMI programming standards. Establish consistent naming conventions, program structures, alarm strategies, diagnostic methods, and documentation requirements. Develop reusable logic modules, Add-On Instructions, function blocks, HMI objects, templates, and software libraries. Lead the migration or alignment of legacy controls programs with approved standards and reusable architectures. Conduct technical design reviews and periodic audits to assess compliance with established controls standards. Identify opportunities to reduce engineering effort, improve maintainability, and increase consistency across equipment and manufacturing lines. Establish appropriate software backup, change-management, release-management, and version-control practices for PLC, HMI, and robot programs. Maintain standard technical documents, implementation guidelines, checklists, and validation procedures. Support the structured rollout and adoption of new controls standards across relevant plants, programs, or production lines.

PLC and HMI Engineering

Develop, modify, debug, validate, and support PLC applications using platforms such as Allen-Bradley Studio 5000, Siemens TIA Portal, or equivalent industrial controls platforms. Develop and maintain HMI applications using platforms such as FactoryTalk View, Siemens WinCC, or equivalent technologies. Review and optimize PLC program architecture, sequencing, interlocks, alarms, fault handling, and equipment diagnostics. Support commissioning, production launch, equipment integration, and continuous-improvement activities. Ensure that controls programs are appropriately documented, tested, backed up, and maintained. Support the implementation of effective equipment recovery, troubleshooting, and diagnostic features.

Manufacturing Execution System Integration

Support and troubleshoot interfaces between manufacturing equipment, PLCs, supervisory systems, and Manufacturing Execution Systems. Investigate data-quality, equipment-status, production-tracking, and system-integration issues. Support industrial data exchange using technologies such as Open Platform Communications Unified Architecture, commonly known as OPC UA. Collaborate with MES and information technology teams to maintain reliable communication between shop-floor controls and manufacturing applications. Help ensure the accuracy, availability, and integrity of manufacturing data.

Industrial Connectivity and IIoT

Support the implementation and troubleshooting of Message Queuing Telemetry Transport, or MQTT, and other industrial data communication solutions. Support Industrial Internet of Things gateways, edge devices, sensors, communication brokers, and associated data pipelines. Develop or maintain standard configurations for industrial connectivity solutions. Support technologies such as Sparkplug B, Ignition, Kepware, or equivalent industrial integration platforms where applicable. Work with information technology and operational technology teams to ensure industrial connectivity solutions meet applicable networking, cybersecurity, reliability, and data-governance requirements. Support the availability of manufacturing data for approved monitoring, reporting, and analytical applications.

Robotics

Support troubleshooting, program review, and optimization for industrial robotic systems. Work with robot platforms such as FANUC, ABB, or equivalent industrial robotics technologies. Coordinate with controls engineers, equipment suppliers, integrators, and production teams to resolve robot-related manufacturing issues. Support robot program backup, change control, documentation, and recovery procedures. Identify opportunities to improve robot reliability, cycle performance, diagnostics, and maintainability.

Forward Model Program Support

Support automation planning, technical reviews, equipment integration, commissioning, and production launch activities for forward model programs. Review supplier and system-integrator controls designs for compliance with approved technical standards. Participate in design reviews, software reviews, equipment acceptance activities, and launch-readiness assessments. Identify automation risks and recommend appropriate technical countermeasures. Capture lessons learned from launches and production support activities and incorporate them into future standards and program requirements.

Technical Leadership and Documentation

Serve as a technical subject-matter expert for controls and industrial automation. Provide technical guidance and mentoring to engineers, technicians, manufacturing teams, and support personnel. Create standard operating procedures, technical specifications, troubleshooting guides, training materials, and engineering standards. Facilitate technical reviews, problem-solving sessions, and knowledge-sharing activities. Communicate technical risks, recommendations, issue status, and implementation plans clearly to technical and non-technical stakeholders. Promote continuous improvement, technical discipline, knowledge sharing, and the consistent application of engineering standards.

Education

Bachelor’s degree in Electrical Engineering, Electronics Engineering, Instrumentation Engineering, Mechatronics Engineering, Control Systems Engineering, Automation Engineering, or a closely related discipline. An equivalent combination of relevant education and significant industrial automation experience may be considered, subject to organizational policy.

Required Experience

Approximately 6 to 10 years of relevant experience in industrial automation, controls engineering, PLC programming, or manufacturing systems. Strong hands-on experience developing, troubleshooting, and maintaining PLC applications. Experience developing or supporting industrial HMI applications. Experience troubleshooting production equipment and resolving manufacturing automation issues. Experience performing root-cause analysis and implementing permanent corrective actions. Experience documenting controls standards, technical procedures, or engineering best practices. Experience collaborating with manufacturing, maintenance, engineering, information technology, suppliers, or system integrators.

Required Technical Knowledge

Strong knowledge of PLC programming principles, industrial controls architecture, sequencing, interlocks, alarms, and equipment diagnostics. Experience with at least one major PLC platform, such as: Allen-Bradley ControlLogix or CompactLogix using Studio 5000 Siemens SIMATIC using TIA Portal An equivalent industrial PLC platform Experience with HMI development using FactoryTalk View, Siemens WinCC, or an equivalent platform. Working knowledge of industrial communication systems and protocols. Understanding of industrial Ethernet and shop-floor network fundamentals. Ability to read and interpret controls documentation, electrical drawings, network architecture diagrams, and equipment specifications. Strong technical documentation and structured problem-solving skills. Experience Level Senior Level