PLC and Motion Control Supervisor – Assembly Robotics

The Mid-Level PLC and Motion Control Supervisor is responsible for supervising a team of automation technicians and engineers focused on PLC programming, motion control systems, and robotics integration within automated assembly lines. This role balances hands-on technical troubleshooting with team leadership and continuous improvement in production automation systems.

Key Focus Areas:

1. Team Supervision & Workflow Management

• Lead a team of technicians and junior engineers on PLC/motion support across shifts.

• Assign tasks, monitor performance, and ensure timely resolution of system issues.

• Serve as the first point of escalation for technical faults and breakdowns.

2. PLC Programming & Troubleshooting

• Modify and optimize PLC code (Siemens, Allen-Bradley, Mitsubishi, etc.).

• Diagnose logic faults, I/O errors, and program logic misalignments during production.

• Ensure version control, backups, and documentation of PLC programs.

3. Motion Control Systems Oversight

• Manage configuration, tuning, and diagnostics of motion controllers, servo drives, and VFDs.

• Oversee integration and alignment of actuators, encoders, and feedback loops in robotic systems.

• Work closely with machine builders to update or troubleshoot motion profiles.

4. Robotics Interface & System Integration

• Supervise the interface between PLCs and robotic arms (ABB, Fanuc, KUKA, UR, etc.).

• Support team in resolving robotic handshakes, cycle faults, and safety I/O issues.

• Validate integration logic during equipment commissioning and retrofits.

5. Preventive Maintenance & Reliability

• Develop and oversee preventive maintenance schedules for PLCs and motion hardware.

• Analyze recurring faults to identify systemic issues and recommend improvements.

• Collaborate with reliability teams to improve uptime of automation assets.

6. HMI & Control Systems

• Modify HMI screens and logic to enhance operator usability.

• Ensure alarms, diagnostics, and status messages are accurate and user-friendly.

7. Compliance & Safety

• Ensure all control systems comply with electrical and safety standards (e.g., IEC, NFPA 70E).

• Lead safety audits and enforce LOTO and arc flash protocols.

• Train team members on electrical safety and robot safety standards (R15.06, ISO 10218).

8. Documentation & Change Management

• Maintain updated schematics, wiring diagrams, and automation manuals.

• Oversee engineering change control for logic modifications and hardware updates.

9. Continuous Improvement & Projects

• Drive improvements in automation cycle times, fault recovery, and control panel designs.

• Lead Kaizen initiatives related to automation and controls.

• Participate in CAPEX projects involving new equipment, automation lines, or upgrades.

Qualifications:

• Education:

  • Diploma or Bachelor's degree in Electrical, Electronics, Mechatronics, or Automation Engineering.

• Experience:

  • 4–7 years of experience in PLC and motion control in a manufacturing or assembly robotics environment.

  • Supervisory or lead technician experience is highly preferred.

• Technical Skills:

  • Proficient in PLC platforms (Siemens TIA Portal, Allen-Bradley RSLogix/Studio 5000).

  • Solid knowledge of motion systems: servo motors, VFDs, linear actuators.

  • Familiarity with industrial networks: Profinet, EtherNet/IP, DeviceNet, etc.

  • HMI development and SCADA exposure is a plus.

Soft Skills:

• Leadership and mentoring abilities

• Strong troubleshooting and decision-making under pressure

• Effective communication across cross-functional teams

• Continuous learning mindset and process-oriented thinking