Maintenance Automation Sr. Engineer

About Lucid

At Lucid, we are pioneering exceptional mobility experiences through relentless innovation to propel the world forward. Our proprietary technology and software-defined vehicle architecture underpin award-winning vehicles that embody our “Compromise Nothing™” philosophy. This commitment is evident in the Lucid Air and Lucid Gravity, where we have redefined automotive segments by delivering unparalleled range, performance, design, and spaciousness in a single, cohesive experience. Our approach is rooted in deep vertical integration, with design, engineering, and production seamlessly coordinated across our global offices and manufacturing facilities. Our diverse teams, drawn from industries worldwide, share a unified dedication to excellence, enabling us to push the boundaries of what’s possible and shape the future of mobility.

Position Overview

The Maintenance Automation Sr. Engineer (PLC) is a pivotal leadership role responsible for the development, commissioning, optimization, and sustainment of advanced automation systems within a high-volume automotive Paint Shop environment. This position ensures the seamless integration and peak performance of robotic, PLC, HMI, and SCADA systems across all critical paint processes, including pre-treatment, e-coat, primer, basecoat, clearcoat, ovens, and final inspection. The engineer will oversee the entire automation lifecycle, from system specification and programming to commissioning, troubleshooting, and continuous improvement. Collaborating closely with maintenance, controls, quality, and production teams, this role is essential in ensuring automation systems meet stringent uptime, quality, safety, and throughput targets while adhering to OEM standards and regulatory requirements.

Key Responsibilities

• Automation System Design & Programming:
  • Design and implement control strategies for robotic and automated systems in paint booths, sealer areas, and utilities.
  • Develop, modify, and optimize PLC logic using Siemens S7/TIA Portal, Allen-Bradley, and Beckhoff platforms.
  • Program and refine robot paths and paint parameters for ABB IRB5500, Fanuc R-2000iC, KUKA KR series, and Dürr EcoRP systems.
  • Design and integrate HMI/SCADA interfaces for alarms, diagnostics, and real-time data visualization.
• Commissioning & Project Execution:
  • Lead automation commissioning for new installations, upgrades, and expansions within the paint shop.
  • Support Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT), including I/O validation, safety interlock testing, and functional verification.
  • Optimize takt time, cycle time, and line balancing during ramp-up phases to enhance operational efficiency.
• Integration & Data Systems:
  • Integrate automation systems with Manufacturing Execution Systems (MES), Quality Management Systems (QMS), SCADA, and traceability platforms.
  • Support vision systems for defect detection and robotic path correction to ensure precision and quality.
  • Deploy and maintain OPC-UA/MQTT and IoT-based monitoring systems to enhance system visibility and performance.
• Process Monitoring & Optimization:
  • Analyze key performance indicators (KPIs) such as First-Time Quality (FTQ), uptime, overspray, paint usage, and rework rates to identify areas for improvement.
  • Implement automation-driven improvements to reduce energy and material consumption, driving sustainability and cost efficiency.
  • Develop predictive maintenance strategies using historical automation data to minimize downtime and enhance reliability.
• Safety, Quality & Compliance:
  • Ensure compliance with international safety standards, including CE, ISO 13849, OSHA, and NFPA 79.
  • Conduct risk assessments and update safety circuits using platforms such as Pilz, Siemens, and SICK to mitigate hazards.
  • Implement poka-yoke systems to prevent errors and enhance quality assurance in paint operations.
  • Support audits and certifications related to paint operations and automation systems to maintain regulatory compliance.
• Documentation & Training:
  • Create and maintain comprehensive electrical/pneumatic schematics using EPLAN, PLC/HMI backups, FMEA reports, and robot backups.
  • Develop Standard Operating Procedures (SOPs) and training modules for maintenance and production teams to ensure operational consistency.
  • Maintain automation change logs and version control systems to track system evolution and ensure traceability.

Skills

• Technical Skills:
  • Expertise in PLC programming and systems, including Siemens S7/TIA Portal, Allen-Bradley, and Beckhoff.
  • Proficiency in robotics, including ABB, Fanuc, KUKA, and Dürr paint robots, with a focus on path programming and parameter optimization.
  • Strong knowledge of SCADA/HMI design, configuration, and diagnostics to enhance system monitoring and control.
  • Comprehensive understanding of paint shop automation, including conveyors, ovens, electrostatic systems, and air handling systems.
  • Advanced electrical troubleshooting capabilities to diagnose and resolve complex system issues efficiently.