The Senior PLC and Motion Control Supervisor is a leadership role responsible for overseeing the deployment, performance, and continuous improvement of PLC-based control and motion systems across automated assembly robotics. This role combines deep technical expertise with cross-functional leadership to ensure system reliability, compliance, and strategic automation upgrades across production lines.
Lead the controls and motion engineering team with focus on system optimization and operational excellence.
Set automation control strategies to align with plant digitalization and smart manufacturing goals.
Serve as subject matter expert (SME) in PLC, motion, and robotics integration across the organization.
Architect and oversee advanced PLC logic using Siemens TIA Portal, Rockwell Studio 5000, or equivalent.
Standardize code libraries, reusable modules, and structured programming best practices.
Supervise high-level diagnostic routines and predictive control algorithms.
Lead tuning, diagnostics, and performance validation of servo systems, drives, and motion controllers.
Interface motion control strategies with robotic systems to enhance speed, repeatability, and accuracy.
Evaluate and approve specifications for new motion control components and upgrades.
Direct complex robotic system integration (e.g., Fanuc, ABB, KUKA, UR) with PLCs and HMIs.
Oversee robot communication protocols, tool changers, safety zoning, and error handling logic.
Lead commissioning teams for new robotic cell deployment and retrofits.
Manage and mentor a team of PLC engineers, motion control technicians, and automation specialists.
Drive training programs on PLC/Motion troubleshooting, safety standards, and documentation.
Support performance reviews, resource planning, and succession development.
Analyze production data and machine diagnostics to drive fault reduction and uptime improvement.
Implement Industry 4.0 tools (IIoT, predictive analytics, remote diagnostics) for system monitoring.
Champion root cause analysis and reliability-centered maintenance.
Ensure control systems meet electrical and safety regulations (IEC 60204, ISO 13849, NFPA 79/70E).
Oversee implementation of functional safety (SIL, PL ratings), emergency stop circuits, and interlocks.
Collaborate with EHS teams on audits and corrective action plans.
Maintain detailed documentation: wiring diagrams, control schematics, logic flowcharts, and panel layouts.
Establish and enforce standard operating procedures (SOPs) and change management protocols.
Work with production, quality, maintenance, and IT teams on automation expansion and improvement.
Lead automation planning for capital equipment investments and digital transformation.
Serve as technical lead for vendor selection, FAT/SAT, and system handover.
Education:
Bachelor’s or Master’s degree in Electrical Engineering, Mechatronics, Automation, or related field.
Experience:
8–12 years of hands-on experience with PLC and motion systems, including at least 3–5 years in a leadership/supervisory role within a high-automation environment.
Technical Expertise:
Deep proficiency in Siemens, Allen-Bradley, or Beckhoff PLC systems.
Strong command over servo tuning, motion profiles, and drive systems.
Proficient in robotic interface and motion kinematics.
Visionary leadership and ability to drive strategic automation initiatives
Excellent communication and cross-disciplinary collaboration
Strong analytical and problem-solving capabilities
Ability to handle high-pressure situations and lead troubleshooting efforts