Automation Hardware and Robotics Reliability Engineer

the LEGO Group; Richmond (VA); Hybrid; Confidential; Full time

Benefits offered by this job

Family Care Leave

Insurance

Wellbeing program

Colleague discount

Bonus scheme

Hybrid work policy

Job summary

The LEGO Group in Virginia (Richmond area) seeks an Automation Hardware and Robotics Reliability Engineer to ensure performance and uptime of High Bay Warehouse automation, including conveyors, robotic arms, stacker cranes, and washing equipment, in collaboration with maintenance and vendors.

You will develop PLC logic, lead root-cause analysis, and drive continuous improvement using Lean, 5S, and Kaizen, while maintaining safety and quality across all hardware activities.

Qualifications

• Bachelor's degree in Mechanical, Electrical, or Mechatronics Engineering or equivalent.
• Experience in industrial automation and robotics.
• Proficiency in PLC programming and control systems.

Responsibilities

• Monitor, troubleshoot, and improve automated warehouse hardware and control systems.
• Develop, modify, and validate PLC logic with vendors.
• Lead root cause analysis and implement corrective actions.
• Support integration, commissioning, and upgrades of new hardware.
• Collaborate with maintenance for repairs and preventive maintenance.
• Drive Lean, 5S, Kaizen initiatives.
• Maintain knowledge of AGVs/AMRs and safety standards.

Skills

PLC programming

Troubleshooting

Data analysis

Reading drawings

Lean/Six Sigma

Education

Bachelor's degree in Mechanical, Electrical, or Mechatronics Engineering

Tools

Power BI

SAP

Job description

The Automation Hardware and Robotics Reliability Engineer is responsible for the performance, reliability, and continuous improvement of the physical automation systems within the High Bay Warehouse — including conveyors, robotic arms, stacker cranes, and washing equipment. This role partners closely with hardware vendors and the maintenance team to troubleshoot equipment, refine PLC logic, and drive uptime through proactive engineering and continuous improvement.

Key Responsibilities

• Monitor, troubleshoot, and continuously improve automated warehouse hardware and supporting control systems.
• Develop, modify, and validate PLC logic and control systems in partnership with hardware vendors.
• Lead root cause analysis on equipment failures and implement durable corrective actions.
• Support the integration, commissioning, and upgrading of new hardware components and subsystems.
• Partner with maintenance technicians on repairs, preventive maintenance plans, and reliability improvements.
• Collaborate with hardware vendors to resolve issues, evaluate enhancements, and manage upgrades.
• Drive continuous improvement initiatives using Lean, 5S, and Kaizen methodologies.
• Maintain working knowledge of warehouse automation equipment and mobile robotics (AGVs and AMRs).
• Ensure compliance with safety, quality, and regulatory standards across all hardware-related activities.

ISO Compliance

• Ensure compliance with the Integrated Management System (IMS), including safety and quality standards.
• Maintain and analyze KPI data using tools such as Power BI and SAP.
• Drive continuous improvement initiatives using Lean, 5S, and Kaizen methodologies.
• Maintain working knowledge of warehouse automation equipment and mobile robotics (AGVs and AMRs).
• Ensure compliance with safety, quality, and regulatory standards across all hardware-related activities.

Play your part in our team succeeding

Monitor, manage, and improve state-of-the-art automated warehouse equipment, gaining exposure to advanced systems and technology. Learn the management of an automated warehouse, the operation of new equipment, and contribute directly to LEGO's mission of inspiring and developing the builders of tomorrow. You will work directly with logistics and maintenance staff, as well as leadership and engineering to ensure the success of our state of the art manufacturing facility.

Do you have what it takes?

• Bachelor's degree in Mechanical, Electrical, or Mechatronics Engineering or equivalent experience in warehouse automation.
• Working experience in industrial automation, robotics, or warehouse systems.
• Proficiency in PLC programming and control systems.
• Strong analytical and troubleshooting skills.
• Ability to read and interpret electrical and mechanical drawings.

Preferred

• Familiarity with high-density storage systems and WMS/WES platforms.
• Experience with Lean/Six Sigma methodologies.
• Experience supporting AGV/AMR fleets.

Additional

• Ability to travel globally for training and cross-country collaboration.
• Relocation assistance will not be offered for this position.
• Primarily on-site in a high-bay warehouse environment with regular interaction with automated equipment.
• Occasional off-shift or weekend work required to support production needs or system maintenance.

What’s in it for you?

Compensation

The salary for this position has a range of $84,674.00 - $127,010.00 based on anticipated responsibilities, market benchmarks, and organizational constraints. The LEGO Group carefully considers a wide range of compensation factors, including but not limited to prior experience, skills, expertise, location, internal equity, and other considerations permitted by law. The comprehensive remuneration details, inclusive of benefits, will be communicated upon finalisation of the employment offer.

What’s in it for you?

• Family Care Leave – We offer enhanced paid leave options for those important times.
• Insurances – All colleagues are covered by our life and disability insurance which provides protection and peace of mind.
• Wellbeing – We want you to be your best self, so you’ll have access to the Headspace App and lots of wellbeing initiatives and programs run by local teams where you are based.
• Colleague Discount – We know you'll love to build so from day 1 you will qualify for our generous colleague discount.
• Bonus – We do our best work to succeed together. When goals are reached and if eligible, you'll be rewarded through our bonus scheme.
• Your workplace – When you join the team you'll be assigned a primary workplace location i.e. one of our Offices, stores or factories. Our hybrid work policy means an average of 3 days per week in the office. The hiring team will discuss the policy and role eligibility with you during the recruitment process.

We strive to create a diverse, dynamic and inclusive culture of play at the LEGO Group, where everyone feels safe, valued and they belong.

The LEGO Group is highly committed to equal employment opportunity and equal pay and seeks to encourage applicants from all backgrounds (eg. sex, gender identity or expression, race/ethnicity, national origin, sexual orientation, disability, age, religion and Veteran status) to apply for roles in our team.

We support our employees in being there for the moments that matter in life and celebrate families of all kinds, the loved ones that make us who we are. Being part of the LEGO Group also means taking part in our annual Play Day, playing a part in building a sustainable future and continuing our mission to “inspire and develop the builders of tomorrow.”

The LEGO Group is fully committed to Children’s Rights and Child Wellbeing across the globe. Candidates offered positions with high engagement with children are required to take part in Child Safeguarding Background Screening, as a condition of the offer.

Thank you for sharing our global commitment to Children’s Rights.

We conduct drug screening as a part of our drug free workplace policy and in support of our commitment to the health and safety of our employees.

Online Application Accessibility Statement; which is intended for people with disabilities - LEGO systems endeavors to make www.LEGO.com/jobs accessible to any and all users. If you would like to contact us regarding the accessibility of our web site or need assistance completing the application process, please contact the HR Service Desk at 1.860-763-7777, option #3. Please note, these communication channels should be used for those having difficulty accessing our on-line channels, not to inquire about job opportunities.