Maintenance Lead – PLC, Automation & Robotics

ProLegion; Bengaluru; On-site; INR 1,500,000 - 2,100,000; Full time

Job description

Job Tittle: Maintenance Lead – PLC, Automation & Robotics

Location: Bangalore

Industry: BESS / EV / Lithium-ion Battery / Automated Manufacturing

Experience: 12+ Years

Qualification: B.E./B.Tech. in Electrical / Electronics / Instrumentation / Mechatronics

Role Overview

We are looking for an experienced Maintenance Lead – PLC, Automation & Robotics to lead automation engineering, maintenance, troubleshooting, commissioning, and optimization of highly automated BESS assembly and manufacturing lines.

The ideal candidate should have strong hands‑on expertise in PLC programming, industrial robotics, servo and motion systems, industrial communication networks, laser welding, pneumatics, MES, HMI, and production automation.

Key Responsibilities

• Lead PLC programming, troubleshooting, logic optimization, commissioning, and maintenance using Keyence KV8000, Siemens TIA Portal, Mitsubishi GX Works 2/3, and Omron Sysmac Studio.
• Manage PLC-HMI communication, data logging, machine integration, and production monitoring systems.
• Handle FAT/SAT, machine commissioning, validation, and automation system integration.
• Configure, tune, and troubleshoot servo drives and motion‑control systems, including Inovance and other precision motion platforms.
• Lead operation, programming, path teaching, commissioning, and maintenance of KUKA, Yamaha, and FANUC robots.
• Troubleshoot robotic controllers, servo systems, mechanical issues, communication failures, and programming‑related problems.
• Optimize robotic cycle time and overall equipment performance.
• Manage and troubleshoot industrial communication networks including EtherCAT, PROFINET, CC‑Link, and EtherNet/IP.
• Maintain and troubleshoot distributed I/O systems including Beckhoff, SMC, Elco, and other automation platforms.
• Lead preventive and breakdown maintenance of laser welding systems, including IPG Photonics, Max Photonics, and Carman Haas welding heads/optics.
• Ensure proper alignment, maintenance, and performance of laser and optical systems used in BESS manufacturing.
• Manage SMC and Airtac pneumatic systems, including cylinders, solenoid valves, FRLs, manifolds, and vacuum systems.
• Optimize pneumatic and vacuum systems to improve equipment reliability and reduce compressed‑air consumption.
• Drive improvements in OEE, equipment availability, cycle time, MTBF, and MTTR while reducing recurring breakdowns.
• Plan manpower deployment for breakdown maintenance, preventive maintenance, commissioning, and improvement activities.
• Lead Root Cause Analysis (RCA), CAPA, and continuous improvement initiatives for chronic automation and equipment failures.
• Manage critical automation spares, inventory, AMC/service requirements, and vendor relationships.

Candidate Profile

• 12+ years of experience in automated manufacturing environments.
• Strong hands‑on experience in PLC, robotics, automation maintenance, and troubleshooting.
• Experience in BESS, EV, lithium‑ion battery manufacturing, or other highly automated production environments will be preferred.
• Strong understanding of preventive and breakdown maintenance, RCA, CAPA, OEE, MTBF, and MTTR.
• Ability to lead maintenance teams and coordinate effectively with production, engineering, OEMs, and external vendors.
• Strong problem‑solving and troubleshooting skills with a hands‑on approach