PLC and Motion Control Supervisor – Assembly Robotics

The PLC and Motion Control Supervisor – Assembly Robotics is responsible for overseeing the operation, programming, and maintenance of PLC systems and motion control technology within robotic assembly lines. This role provides technical leadership to a team of automation technicians and engineers, ensures system uptime, and drives continuous improvement in robotic performance, integration, and safety.

Key Focus Areas:

1. Team Leadership & Supervision

• Supervise and support a team of PLC/motion control technicians and junior engineers.

• Assign and prioritize daily maintenance and support tasks for robotic assembly systems.

• Mentor and train staff on troubleshooting, programming, and safety standards.

2. PLC Programming & Optimization

• Oversee development, troubleshooting, and modification of PLC programs (Siemens, Allen-Bradley, Mitsubishi, etc.).

• Ensure optimal cycle times, sequence logic, and communication protocols for assembly line control systems.

• Coordinate with controls engineers to implement software upgrades or bug fixes.

3. Motion Control & Servo Systems

• Manage setup, tuning, and synchronization of servo drives, stepper motors, and motion controllers.

• Support high-speed, multi-axis motion applications in robotics, conveyors, and pick-and-place systems.

• Maintain encoder feedback systems and motion profiles for consistent performance.

4. Robotic Integration

• Oversee integration and interfacing of PLCs with robotic arms (e.g., Fanuc, ABB, KUKA, UR).

• Ensure real-time data exchange and synchronization between robots and upstream/downstream equipment.

• Support robot path programming, I/O mapping, and error handling strategies.

5. System Reliability & Troubleshooting

• Lead root cause analysis for equipment faults, line stoppages, and software-related issues.

• Establish preventive maintenance and diagnostics for PLC and motion hardware.

• Ensure minimal downtime and maximum availability of robotic assembly lines.

6. Standards & Compliance

• Enforce safety regulations and functional safety compliance (e.g., SIL, IEC 62061, ISO 13849).

• Maintain proper documentation of logic diagrams, electrical schematics, and HMI configurations.

7. Continuous Improvement

• Drive initiatives to reduce cycle time, increase yield, and improve energy efficiency.

• Identify automation bottlenecks and suggest control logic or hardware upgrades.

• Support digital transformation projects (e.g., Industry 4.0, predictive maintenance, MES integration).

8. Project Coordination & Commissioning

• Lead control system commissioning during installation of new robotics and upgrades.

• Coordinate with OEMs, suppliers, and internal teams during system deployment.

Qualifications:

• Education:

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

• Experience:

  • 5–8 years of experience in PLC and motion control systems, with at least 2–3 years in a supervisory or lead role.

• Technical Skills:

  • PLC platforms: Siemens S7/TIA Portal, Allen-Bradley ControlLogix, Omron, Mitsubishi, etc.

  • Motion platforms: Siemens S120, Rockwell Kinetix, Yaskawa Sigma, etc.

  • Robotics integration: Fanuc, ABB, KUKA, or Universal Robots

  • Familiarity with HMI/SCADA platforms and industrial networking (EtherNet/IP, ProfiNet, etc.)

Preferred Certifications: