Senior Manufacturing Automation Engineer: PLC, Robotics & OEE

Alloy Enterprises

Lubbock (TX)

On-site

USD 85,000 - 128,000

Full time

14 days+

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Benefits offered by this job

Competitive benefits package

Job summary

Johnson Controls is seeking an Automation Engineer to improve, maintain, and support automated Assembly, Test, and Production systems. You will enhance equipment performance, reliability, OEE, and process capability through advanced automation, PLC programming, and robotics expertise.

You will lead new equipment integration, develop control architectures, document changes, and collaborate with Operations, Maintenance, Quality, and Process Engineering to deliver continuous improvements and

Qualifications

Bachelor’s degree in Electrical Engineering, Mechatronics, Automation Engineering, or related field.
Hands-on experience with PLC programming (Allen-Bradley preferred), HMIs, sensors, robotics, motions systems, and industrial networks.
Strong troubleshooting skills and experience with automated production equipment.
Ability to analyze equipment data and drive improvements in OEE and machine reliability.
Understanding of electrical schematics, controls design, and machine safety standards.
Familiarity with Lean manufacturing principles and continuous improvement.
Advanced troubleshooting and problem solving.
Automation controls & programming.
Cross-functional collaboration.
Root cause analysis (RCA).
Lean manufacturing / continuous improvement principles.
Project management.
Strong documentation and communication skills.
Ownership mindset and accountability.

Responsibilities

Improve performance, uptime, and reliability of automated Assembly and Testing equipment.
Lead troubleshooting of complex automation issues, including PLC logic, sensors, communications, HMIs, robotics, and servo/motion systems.
Conduct root cause analysis for recurring equipment failures and implement permanent corrective actions to reduce downtime and cycle time variability.
Develop, modify, optimize, and maintain PLC programs (Allen‑Bradley / Siemens or plant standards).
Update and improve HMI screens, diagnostics, alarm structures, and operator interfaces.
Maintain robust version control and documentation for all automation code.
Implement and maintain error‑proofing (Poka‑Yoke) logic to prevent defects.
Own OEE improvement initiatives for automated lines—Availability, Performance, Quality.
Analyze performance data and downtime trends to target improvement opportunities.
Optimize machine motion profiles, cycle times, process sequences, and control logic.
Support Process Engineering in eliminating bottlenecks and improving takt adherence.
Lead automation-related activities for new equipment: specification, vendor management, design reviews, and commissioning.
Develop functional specifications, control architecture, and FAT/SAT acceptance criteria.
Support equipment buyoffs, debugging, installation, and process validation.
Identify and deploy new technologies to improve automation capability and efficiency.
Maintain updated electrical schematics, I/O lists, network diagrams, and device documentation.
Support ECNs/ECRs with required automation changes and proper documentation.
Create and maintain technical documentation for operators, Maintenance, and Engineering teams.
Participate in and lead CI/Kaizen events targeting uptime, scrap, cycle-time reduction, and throughput improvement.
Implement data collection, system monitoring, and analytics tools to enhance decision making.
Collaborate with Process Engineering on workflow, line balance, and layout improvements.
Maintain, troubleshoot, and improve automated test equipment, instrumentation, and data acquisition systems.
Ensure test systems meet capability, repeatability, and calibration requirements.
Enhance diagnostic features to speed up troubleshooting and reduce false failures.
Work closely with Quality to improve test capability, Poka‑Yoke coverage, and error detection systems.
Assist Operations in resolving daily automation issues and supporting production recovery efforts.
Partner with Maintenance to ensure reliable, safe, and sustainable operation of automation systems.
Perform other duties as assigned.