Automation Engineer

Description

PURPOSE:

The Automation Engineer is responsible for developing, implementing, maintaining, and improving automated manufacturing systems and processes supporting new and existing products. This role focuses on integrating automation, robotics, controls, and advanced manufacturing technologies to improve safety, quality, delivery, and cost performance.

The position supports new product introduction, production sustainment, and continuous improvement initiatives by identifying automation opportunities, developing technical solutions, troubleshooting equipment and process issues, and collaborating with cross-functional teams. The Automation Engineer works under established technical direction to implement reliable, efficient, and scalable automation solutions aligned with manufacturing objectives.

DUTIES/RESPONSIBILITIES:

1. Automation Development and Integration

• Support the design, development, and implementation of automated manufacturing systems and equipment.
• Identify opportunities to automate manual processes and improve manufacturing efficiency, consistency, and repeatability.
• Assist in the integration of robotics, PLCs, sensors, machine vision, motion control, and other automation technologies.
• Support the development of equipment concepts, functional requirements, specifications, and system layouts.
• Collaborate with manufacturing and design engineering to incorporate Design for Automation (DFA) and Design for Manufacturability (DFM) principles into new products and processes.
• Support the evaluation of emerging automation technologies and their potential manufacturing applications.

2. Equipment Installation, Commissioning, and Qualification

• Support equipment installation, startup, commissioning, and acceptance activities.
• Assist in developing and executing equipment testing, process validation, and qualification plans.
• Verify automated equipment performance against established specifications, safety requirements, and production objectives.
• Coordinate with equipment suppliers, system integrators, and internal technical teams to resolve installation and performance issues.
• Support equipment acceptance testing and the transition of automated systems into production.
• Develop and maintain equipment operating parameters, recipes, and control settings as applicable.

3. Production Support and Troubleshooting

• Provide technical support for automated manufacturing equipment and production processes.
• Troubleshoot automation, controls, sensors, robotics, and equipment-related issues to minimize downtime and production interruptions.
• Identify root causes of recurring equipment failures and implement sustainable corrective actions.
• Collaborate with Operations, Maintenance, Quality, and Engineering to improve equipment reliability and process performance.
• Support the development of preventive maintenance requirements and troubleshooting procedures.
• Assist in monitoring equipment performance, cycle time, uptime, and overall equipment effectiveness (OEE).

4. Lean Manufacturing and Continuous Improvement

• Identify and implement automation and process improvements that enhance safety, quality, delivery, and cost performance.
• Support Lean Manufacturing initiatives, including waste reduction, standardized work, cycle-time improvement, and production flow optimization.
• Analyze manufacturing data to identify trends, process constraints, and opportunities for improvement.
• Participate in root cause analysis, corrective action, and continuous improvement activities.
• Evaluate the effectiveness of implemented automation solutions and recommend further improvements.
• Support efforts to reduce scrap, rework, labor content, and process variability.

5. Project Execution and Supplier Coordination

• Execute assigned automation projects in accordance with established scope, schedule, budget, and technical requirements.
• Assist in preparing equipment specifications, project schedules, cost estimates, and capital expenditure justifications.
• Coordinate with vendors and system integrators to evaluate technical proposals and support equipment selection.
• Track project activities, resolve technical issues, and communicate project status, risks, and resource needs to stakeholders.
• Support equipment procurement, factory acceptance testing, site acceptance testing, and project closeout.
• Identify opportunities to reuse proven automation designs and standard components across manufacturing processes.

6. Documentation and Standardization

• Develop and maintain automation documentation, including equipment specifications, electrical schematics, control narratives, operating procedures, and troubleshooting guides.
• Support the development and maintenance of PLC programs, HMI configurations, robot programs, and related technical files in accordance with company standards.
• Maintain appropriate revision control, backups, and documentation for automation systems.
• Establish and follow standard practices for equipment installation, operation, troubleshooting, and maintenance.
• Support the development of standardized automation platforms, components, and control practices under the direction of senior technical personnel.
• Ensure documentation supports safe operation, repeatable processes, and effective knowledge transfer.

7. Safety, Quality, and Compliance

• Incorporate appropriate machine safety, guarding, interlocking, and risk-reduction measures into automation projects.
• Support machine risk assessments and compliance with applicable OSHA requirements, recognized industrial safety standards, and company procedures.
• Collaborate with Quality Engineering to ensure automated processes meet product specifications and quality requirements.
• Support process capability studies, equipment qualification, and corrective action activities as required.
• Ensure automation changes are appropriately reviewed, documented, tested, and released before implementation in production.

8. Cross-Functional Collaboration and Technical Development

• Work closely with Manufacturing Engineering, Operations, Maintenance, Quality, Product Development, IT, and external suppliers.
• Participate in new product introduction activities to ensure manufacturing equipment and automation requirements are addressed.
• Communicate technical issues, project progress, and improvement opportunities to engineering leadership and manufacturing stakeholders.
• Develop technical expertise in automation, robotics, controls, and manufacturing systems.
• Share lessons learned and contribute to continuous improvement of engineering practices.
• Apply established automation standards and incorporate feedback from senior engineers to improve technical performance and project execution.

Requirements

EDUCATION AND/OR PROFESSIONAL LICENSE(s):

• Bachelor of Science degree in Mechanical, Electrical, Mechatronics, Manufacturing, Industrial Engineering, or related technical field required
• Relevant technical certifications in automation, robotics, PLC programming, or industrial controls preferred
• Training or certifications in Lean Manufacturing, Six Sigma, or continuous improvements preferred

EXPERIENCE:

• 1-5 years of experience in manufacturing engineering, automation engineering, controls engineering, or a related technical field.
• Experience with automated manufacturing equipment, industrial controls, robotics, or system integration preferred.
• Experience supporting equipment installation, commissioning, troubleshooting, and process qualification preferred.
• Experience working in cross-functional engineering, manufacturing, and product development teams preferred.
• Exposure to aerospace, defense, composite manufacturing, or other regulated manufacturing environments is a plus.

KNOWLEDGE, SKILLS AND ABILITIES:

• Working knowledge of manufacturing automation, industrial controls, and automated production systems.
• Familiarity with PLC programming, HMI systems, sensors, actuators, and industrial electrical systems.
• Understanding of robotic systems, machine vision, motion control, and automated material handling.
• Ability to interpret electrical schematics, mechanical drawings, equipment layouts, and technical specifications.
• Familiarity with automation programming and troubleshooting tools, including Allen-Bradley, Siemens, or comparable control platforms, preferred.
• Understanding of machine safety, risk assessments, guarding, and applicable industrial safety standards.
• Working knowledge of Lean Manufacturing, root cause analysis, and continuous improvement principles.
• Ability to evaluate manufacturing processes and identify opportunities for automation, cycle-time reduction, and quality improvement.
• Familiarity with CAD tools, manufacturing data systems, and equipment documentation.
• Basic understanding of project management, equipment specifications, capital expenditures, and return-on-investment evaluations.
• Strong analytical, troubleshooting, and problem-solving skills.
• Hands-on approach with the ability to work effectively on the manufacturing floor.
• Strong written and verbal communication skills and the ability to collaborate across engineering, operations, quality, and external suppliers.

POSITION SUPERVISES (by department name or job title):

• Individual contributor role
• May coordinate activities with technicians, operators, and cross-functional team members
• No direct supervisory responsibilities

CONTACT WITH OTHERS:

• Frequent interaction with engineering, operations, quality, and supply chain teams
• Regular communication with suppliers and occasional interaction with customers

PHYSICAL / WORK ENVIRONMENT:

• Combination of office and manufacturing floor environment
• Exposure to varying temperatures, noise levels, and production conditions
• Ability to lift up to 50 lbs. and perform typical physical activities (standing, walking, bending, etc.)

TRAVEL:

Limited travel required

LOCATION:

Gentex’s Carbondale facility is located in Northeastern Pennsylvania in Lackawanna County. Carbondale, PA is about twenty miles north of Scranton, PA, 50 miles south of Binghamton, NY, and about 125 miles from New York City and Philadelphia. The area hosts numerous nearby state parks, nature preserves and local colleges and universities, including The University of Scranton and Marywood University. Northeast Pennsylvania is a beautiful area and offers an excellent cost of living. It is a great place to work, recreate, meet people, raise a family and live!

Gentex Corporation is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard for any applicable state or federal protected class. Gentex is an E-Verify Participant. Pre-employment drug/alcohol/background screening is required.