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Key Responsibilities and Required Skills for Automation Technician

💰 $ - $

EngineeringManufacturingMaintenanceAutomation

🎯 Role Definition

An Automation Technician installs, programs, tests, maintains, and troubleshoots industrial automation equipment and control systems to ensure safe, efficient, and continuous production operations. This hands-on role requires a mix of electrical, electronic, and mechanical skills including PLC and HMI programming, SCADA support, robotics and motion system maintenance, VFD and motor control, sensor calibration, and industrial network diagnostics. The Automation Technician partners closely with production, engineering, quality, and safety teams to implement process improvements, maintain documentation, and support plant uptime goals while complying with safety and regulatory requirements.

Key search terms: Automation Technician, PLC technician, controls technician, industrial automation, electrical troubleshooting, HMI, SCADA, robotics maintenance, preventative maintenance, industrial networks.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Electrical Technician or Maintenance Technician
  • Industrial Electrician Apprentice or Journeyman
  • Mechatronics or Controls Apprentice / Intern

Advancement To:

  • Senior Automation Technician / Lead Technician
  • Controls Engineer / Automation Engineer
  • Maintenance Supervisor / Engineering Supervisor
  • Reliability Engineer

Lateral Moves:

  • Robotics Technician
  • Instrumentation Technician
  • Process Technician
  • PLC Programmer

Core Responsibilities

Primary Functions

  • Install, commission, and validate PLC, HMI, and SCADA systems on production lines, including ladder logic and structured text programming, I/O mapping, and HMI screen development to meet engineering specifications and production requirements.
  • Troubleshoot and repair electrical control systems (up to 480 VAC) including relays, contactors, motor starters, and circuit protection devices by interpreting electrical schematics, ladder logic, and P&ID drawings.
  • Diagnose and resolve PLC logic faults, communication errors, and intermittent system issues using vendor tools (e.g., Rockwell/Allen‑Bradley RSLogix/Studio 5000, Siemens TIA Portal, Schneider EcoStruxure) and on-board diagnostics to restore production quickly and safely.
  • Maintain and program HMI panels (PanelView, Pro-face, Weintek, Siemens WinCC) and SCADA systems, updating screens and alarm configurations to improve operator usability and incident response.
  • Perform preventative and predictive maintenance on automation assets: VFDs, servo drives, motors, encoders, proximity and photoelectric sensors, pneumatic actuators, and robotic end‑of‑arm tooling to reduce unplanned downtime.
  • Commission and support industrial robots (ABB, FANUC, KUKA, Yaskawa) including teach pendants, robot program edits, cell safety interlocks, and integration with conveyors and vision systems.
  • Troubleshoot and repair variable frequency drives (VFDs) and motor control systems, perform parameter checks, and run motor start/stop and speed-tuning procedures to ensure proper motion control and process stability.
  • Conduct electrical and control panel wiring, terminations, and cable management following NEC and company standards; build and modify control enclosures as required for upgrades and retrofits.
  • Test, calibrate, and certify instrumentation and sensors (pressure, temperature, flow, level) and integrate instrumentation with PLC and DCS systems to achieve accurate process control.
  • Diagnose and repair industrial network issues (EtherNet/IP, ProfiNet, Modbus TCP/RTU, DeviceNet) including network switches, IP addressing, and segmentation to support reliable device communications.
  • Implement and document control system changes using change control processes, version control, and backup procedures; maintain clear revision histories and as-built documentation.
  • Support startup and shutdown procedures for lines and equipment, providing technical leadership during planned maintenance windows and unplanned production events.
  • Use CMMS (e.g., Maximo, SAP PM) to generate work orders, document maintenance activities, record spare parts usage, and track mean time between failures (MTBF) and mean time to repair (MTTR).
  • Perform root cause analysis (RCA) after failures using structured methodologies (5 Whys, Fishbone, FMEA) and drive corrective actions and continuous improvement projects to increase equipment reliability.
  • Participate in commissioning activities for capital projects and equipment upgrades including FAT/SAT support, wiring verification, loop checks, and functional testing against engineering specifications.
  • Execute safety checks and ensure compliance with lockout/tagout (LOTO), NFPA 70E, machine guarding and local safety standards while servicing energized equipment when authorized.
  • Train production operators and maintenance staff on proper operation, basic troubleshooting, and routine maintenance tasks for automation equipment to empower first-line response and reduce downtime.
  • Collaborate with process and control engineers to develop and optimize control strategies, PID tuning, sequencing, and interlock logic for robust, repeatable manufacturing processes.
  • Source, maintain, and manage critical spares inventory for control and automation components, recommend stocking levels, and coordinate with suppliers for expedited parts procurement when needed.
  • Prepare clear technical documentation, maintenance procedures, BOMs, and work instructions for control systems and automation assets to support knowledge transfer and compliance audits.
  • Execute electrical and control upgrades to improve efficiency, reduce energy consumption, and support digitalization initiatives such as IIoT data collection and condition monitoring.
  • Support equipment validation and quality programs, performing checks and documenting results to meet regulatory and customer requirements in FDA, ISO, or other controlled environments.
  • Lead small project implementations and vendor coordination activities, ensuring milestones, testing plans, and commissioning schedules are met on time and within budget.
  • Maintain awareness of emerging automation technologies and propose pilot projects or upgrades to keep the plant competitive and reduce lifecycle costs.

Secondary Functions

  • Support operator-level continuous improvement events and Kaizen workshops by providing technical guidance on automation-related opportunities.
  • Respond to ad-hoc data requests from engineering and operations by extracting event logs, PLC data, and alarm histories for analysis.
  • Contribute to digital transformation initiatives by assisting with IIoT sensor deployment, edge device configuration, and historian integration (OSIsoft/PI, Wonderware).
  • Participate in safety and audit activities, ensuring documentation is ready for internal and external inspections and remediation actions are tracked to closure.
  • Assist procurement and vendor management with technical specifications, acceptance criteria, and site installation guidance to streamline equipment deliveries and installations.
  • Mentor junior technicians and apprentices through on-the-job training, documented procedures, and hands-on coaching to develop team capability.
  • Help maintain calibration schedules, records, and certificates for critical instruments and automation devices.
  • Participate in cross-functional meetings (production, quality, engineering) to align on priorities, outages, and improvement plans.
  • Keep software and firmware inventories current, coordinate updates and security patches with IT and control engineering teams to minimize cyber risk.

Required Skills & Competencies

Hard Skills (Technical)

  • PLC programming and troubleshooting (Allen‑Bradley/Rockwell RSLogix & Studio 5000, Siemens TIA Portal, Mitsubishi, Schneider).
  • HMI/SCADA configuration and support (PanelView, WinCC, FactoryTalk View, Ignition).
  • Industrial networking: Ethernet/IP, Profinet, Modbus TCP/RTU, DeviceNet, and basic network troubleshooting (switches, VLANs, IP addressing).
  • Robotics and motion control: robot cell troubleshooting, teach pendants, servo drives, encoder diagnostics (ABB, FANUC, KUKA, Yaskawa).
  • Variable Frequency Drives (VFDs) and motor control (ABB, Danfoss, Siemens), including parameterization and fault resolution.
  • Electrical wiring and control panel assembly, reading schematics, ladder diagrams, P&IDs and conduit/cable routing.
  • Instrumentation and process control fundamentals: PID tuning, sensor calibration, process loops.
  • Diagnostic tools and test equipment: multimeter, clamp meter, insulation tester, oscilloscope, signal generator.
  • Preventative and predictive maintenance methodologies, CMMS usage (Maximo, SAP, eMaint).
  • PLC code backup/version control, change management and functional testing (FAT/SAT).
  • Familiarity with safety standards and practices: LOTO, NFPA 70E, machine guarding, SIL basics.
  • Basic scripting or data manipulation (Excel, SQL queries or Python) for extracting troubleshooting data or trends.
  • Basic knowledge of pneumatics and hydraulics for valve and actuator troubleshooting.

Soft Skills

  • Strong analytical and systematic problem-solving skills to isolate intermittent faults and complex automation issues.
  • Clear verbal and written communication for cross-functional coordination, operator training, and documentation.
  • Attention to detail when working with wiring, firmware, and control logic to avoid process or safety incidents.
  • Ability to prioritize work under pressure and manage multiple corrective and preventative maintenance tasks.
  • Team player mindset with the ability to lead small projects and mentor less-experienced technicians.
  • Continuous improvement orientation; comfortable driving and accepting change to improve equipment reliability.
  • Strong organizational skills for maintaining documentation, spares lists, and maintenance logs.
  • Customer- and production-focused attitude to balance technical fixes with operational uptime goals.
  • Adaptability to learn new automation platforms and vendor-specific tools quickly.

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED with vocational training or certification in industrial electricity, mechatronics, or automation technology.

Preferred Education:

  • Associate degree or technical diploma in Electrical Technology, Mechatronics, Instrumentation, Industrial Maintenance, or Automation Engineering Technology.
  • Certifications such as IPC, Rockwell/Siemens certified training, OSHA, NFPA 70E qualification, or robotics vendor certification are a plus.

Relevant Fields of Study:

  • Electrical or Electronic Technology
  • Mechatronics / Automation Technology
  • Instrumentation and Controls
  • Mechanical or Industrial Engineering Technology

Experience Requirements

Typical Experience Range: 2–5 years of hands-on experience in industrial automation, controls, or maintenance roles.

Preferred:

  • 3–7 years supporting PLC/HMI systems, industrial networks, VFDs, and robotic systems in a manufacturing or processing environment.
  • Demonstrated experience commissioning new equipment, performing FAT/SAT, executing RCA, and delivering continuous improvement projects.
  • Prior exposure to regulated environments (pharmaceutical, food & beverage, chemical) or complex process control systems is beneficial.
  • Experience with CMMS systems, vendor coordination, and spare parts management.
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