Staff Controls, Automation & Mechatronics Engineer

ZT Systems; Georgetown, Northern (TX, KY); Hybrid; USD 110,000 - 170,000; Full time

Job summary

ZT Systems is seeking a Staff Controls, Automation & Mechatronics Engineer to design and implement advanced automation solutions across server manufacturing. This role blends mechanical, electrical, and software systems to improve yield, reliability, cycle time and scalability.

You will drive DFMA and DFA, develop scalable automation for NPI, integrate robotics, PLCs, vision systems, and data-driven methods to enable smarter, faster production.

Qualifications

• 8+ years of experience in high-volume, high-complexity manufacturing.
• Background in electronics assembly, servers, or high-reliability industries.
• Proficiency with data-driven tools to analyze large datasets (e.g., Python, R, SQL).
• Experience implementing automated production lines and robotic cells.
• Strong CAD skills and knowledge of industrial automation platforms.
• Experience with DFMA and DFA principles embedded in product designs.

Responsibilities

• Contribute to transformation initiatives and set new manufacturing standards.
• Define and implement new automation systems and frameworks for smart factory vision.
• Support NPI with scalable automation strategies.
• Design and implement automated assembly and test equipment for server components.
• Collaborate to embed DFM and DFA in product designs.
• Translate PFMEA outputs into actionable process controls.
• Develop and optimize mechatronic systems with robotics, sensors, PLCs, vision, motion, and software.
• Use data-driven methods to improve yield, reliability, cycle time, and throughput.
• Work with vendors to install automation solutions for production.
• Implement automated inspection and testing systems; maintain safety and compliance.

Skills

PLC programming

HMI/SCADA

Motion control

PID control

Robotics integration

Vision systems

Python

C/C++

Matlab/Simulink

Data analytics

Education

Advanced degree in Engineering, CS, Data Science, or related field

Tools

SolidWorks/AutoCAD

Siemens

Allen-Bradley

OpenCV

Job description

**About The Role**The Staff Controls, Automation & Mechatronics Engineer will be at the forefront of designing and implementing advanced automation solutions that drive efficiency, scalability, and quality in our server manufacturing operations. This role requires a strong foundation in Controls and mechatronics engineering, combining mechanical, electrical, and software systems to develop integrated automation solutions. They will leverage mechatronics principles to enhance system performance, reliability, and scalability while collaborating across disciplines to support rapid deployment and continuous improvement. **What You Will Do*** Contribute to transformation initiatives, helping set new standards for how ZT approaches manufacturing risk analysis, quality, and continuous improvement.* Define and implement new systems, processes, or frameworks that support the smart factory vision, including automation, metrology, advanced inspection and testing, and predictive analytics.* Support NPI (New Product Introduction) by developing scalable automation strategies aligned with product roadmaps.* Design and implement automated assembly and test equipment for server components, including PCBs, power modules, and cooling systems.* Collaborate with cross-functional teams to ensure Design for Manufacturability (DFM) and Design for Automation (DFA) Principals are embedded in new product designs.* Translate DFM and PFMEA outputs into actionable process controls, ensuring proactive prevention of variation rather than reactive correction.* Develop and optimize mechatronic systems integrating robotics, sensors, actuators, PLCs, vision systems, motion control and software.* ·Leverage deep, data-rich environments and tools to generate insights and drive continuous improvement initiatives focused on yield, reliability, cycle time, and throughput.* Work with equipment vendors to specify, validate, and install automation solutions for medium to high-volume production.* Apply manufacturing techniques such as precision fastening, soldering, adhesive bonding, and vision-based inspection.* Lead tool qualification, process documentation, and operator training for new equipment.* Use data-driven methods (e.g., SPC, FMEA, DOE) to troubleshoot and enhance manufacturing performance.* Analyze production workflows to identify automation opportunities & optimize cycle times, throughput, and reliability of automated systems.* Implement automated inspection and testing systems to ensure product quality.* Maintain compliance with safety, environmental, and industry standards.* Create detailed documentation for automated systems, including SOPs and training materials. Provide technical support and training to production teams. **What You Bring**The right person for this role is an agent of change and has exceptional analytical capabilities, thrives in a fast-paced environment, loves problem-solving, is a good communicator, and is passionate about enabling the future of cloud computing.* Advanced degree in Engineering, Computer Science, Data Science, or a related field.* 8+ years of experience in high-volume, high-complexity manufacturing.* Proficiency with data-driven tools such as Minitab, JMP, Python, R, SQL (or equivalent) to analyze and interpret large, complex datasets.* Track record of driving measurable improvements in yield, reliability, or process robustness.* Background in electronics assembly, PCBA, servers, or other high-reliability industries (e.g., aerospace, medical devices, automotive, semiconductor etc.).* Proficiency in CAD tools (SolidWorks, AutoCAD) and industrial automation platforms (Siemens, Allen-Bradley, etc.). **Controls Engineering Skills**Advanced proficiency in:* PLC programming (Codesys, Siemens, Beckhoff...)* HMI/SCADA development* Motion control (servo, stepper systems) Designing and tuning:* PID loops* Multi-axis control systems* High-speed machine control Automation SystemsDesign, commissioning, and optimization of:* Automated production lines* Robotic cells* Automated test equipment* Material handling & conveyance systems* Industrial protocols (EtherCAT, Ethernet/IP, ProfiNet, Modbus TCP)* Control architectures & safety systems Mechanical & Mechatronics SystemsStrong mechanical understanding: actuators, sensors, power transmission, machine design. Experience integrating:* Robotics (Fanuc, Kuka, ABB, UR)* Pneumatics & hydraulics* Vision systems (Cognex, Keyence, OpenCV)* Instrumentation & measurement systemsSoftware & Scripting* Python (automation, data logging, test scripts)* C/C++ (embedded systems)* MATLAB/Simulink (controls modeling)* LabVIEW (optional but valued) **Nice to Haves*** Exposure to or knowledge of AI/ML toolsets for statistical problem solving, predictive analytics, or anomaly detection.* MBA or exposure to business, finance or economics is advantageous.