PLC & Automation Engineer - BIW & Paint Shop

Job Purpose

To ensure smooth operation, optimization, and reliability of automation and control systems in the BIW (Body Shop) and Paint Shop by performing preventive, predictive, and corrective maintenance of PLCs, robots, and other related equipment’s, while supporting continuous improvement projects to enhance equipment uptime, quality, and energy efficiency.

Key Responsibilities

Projects

• Validate RFQ – Coordinate for Installation & Commissioning of automation systems in Paint/BIW projects
• Solution development & validation in discussion with suppliers to secure Project deliverables
• Coordinate with vendors , Project , Safety & Maintenance team during project phase
• Ensure equipment installation, commissioning & prove out as per the standard in brown field project
• Provide feedback during engineering phase of the project to vendors and ensure necessary controls are in place for Safety, Quality, Delivery, Cost, Environment, People(SQDCEP) of the process

PLC & Automation System Management

• Handle operation, maintenance, and troubleshooting of PLCs, HMIs, SCADA, and field communication networks (PROFIBUS, PROFINET, Ethernet/IP).
• Maintain and modify logic for PLC’s (Siemens S7-300/400/1200/1500, Allen Bradley ControlLogix, or Mitsubishi PLCs etc)
• Develop, modify, and validate interlocks, safety logics, and process control sequences for both BIW and Paint Shop.
• Perform program backups, documentation, and version control as per plant standards.
• Interface PLCs with robots, drives, and higher-level control systems (MES, SCADA).
• Interface with IT as a key user & train other users

Robotics & Mechatronic Systems

• Maintain and troubleshoot industrial robots in BIW (spot welding, MIG welding, material handling) and Paint Shop (painting, sealing, and sanding robots).
• Work with robot controllers for programming and calibration (Fanuc, ABB, KUKA, or Yaskawa etc.)
• Monitor robot paths, process parameters, and communication with PLCs.
• Support robot re-teaching, parameter tuning, and error recovery for cycle optimization.

BIW (Body-in-White) Systems

• Maintain automation systems in spot welding, framing, and sealer application lines etc.
• Troubleshoot electrical and control systems for welding controllers (Aro, Bosch, Medar, OBARA etc), servo guns, and motion controllers.
• Monitor conveyor control systems, lifters, turntables, and positioning devices.
• Ensure accuracy of interlocks, sensors, limit switches, and field I/O modules.
• Implement process improvements to reduce weld cycle time and enhance equipment reliability.

Paint Shop Systems

• Maintain PLCs, HMIs, and automation for :

• Monitor and control temperature, pressure, humidity, and flow through instrumentation systems.
• Support energy optimization in paint booths, curing ovens, and exhaust fans.

Control Panel & Electrical Maintenance

• Maintain and troubleshoot MCCs, control panels, and field junction boxes.
• Perform load analysis, insulation resistance checks, and earth resistance testing.
• Maintain and test safety relays, interlocks, and E-stops as per EHS standards.
• Ensure compliance with IEC, IS, and EHS safety standards.

Data Monitoring & Continuous Improvement

• Utilize SCADA, MES, and data acquisition systems for monitoring downtime and process parameters.
• Perform Root Cause Analysis (RCA) for recurring automation faults and implement corrective actions.
• Support TPM, Kaizen, and Lean initiatives to improve equipment reliability and reduce energy consumption.
• Develop dashboards for cycle time monitoring, robot downtime, and alarm history analysis.

Documentation & Audit Compliance

• Maintain updated electrical schematics, control logic diagrams, and automation documentation.
• Keep preventive maintenance and calibration records for all automation systems.
• Ensure compliance with IATF 16949, ISO 14001, and ISO 45001 requirements.
• Participate in internal and external audits (EHS, TPM, IATF) with relevant data and reports.

Technical Skills & Competencies

Key Performance Indicators (KPIs)

• BIW & Paint Shop Equipment Uptime (%)
• PLC/Robot Fault Response Time
• Mean Time To Repair (MTTR)
• Mean Time Between Failures (MTBF)
• Energy Consumption per Body/Painted Unit
• PM Compliance (%)
• Recurring Fault Reduction (%)
• Audit Compliance (Safety, Quality, EHS)

Qualification & Experience

• Education: B.E. / B.Tech / Diploma in Electrical, Electronics, Mechatronics
• Experience: 6–10 years in automobile BIW and Paint Shop automation maintenance

Behavioral Competencies

• Strong analytical and problem-solving skills.
• Effective cross-department coordination (Production, Quality, Utilities, EHS).
• High commitment to safety and process discipline.
• Continuous learning mindset for new automation technologies (IoT, Vision, AI).