Job Description
**What you’ll do:**
The Lead Engineer – Industrial Automation will design, commission, and scale fully automated production solutions for ETO electrical assemblies (switchboards, LV assemblies), covering robotics, PLC/motion controls, vision/AI-guided assembly, digital work instructions, and MES/IIoT integration. The role owns URS→FAT→SAT delivery, creates standard cell templates, and leads Eaton’s Industry 4.0 lab: selecting hardware/software, building demonstrators, publishing commissioning playbooks, and training engineers for repeatable deployments across plants.
"• System Architecture & Commissioning Ownership: Convert URS/SRS to detailed control architecture (cells/lines, safety zoning, networks); author FMEA/PFMEA; define ISA‑S88 state machines; lead design reviews, pre‑FAT, FAT, SAT, ramp‑up, handover.
• Robotics Integration (ETO Assembly & Wiring): Flexible robotic cells for panel/enclosure handling, device insertion, torqueing, label OCR, busbar handling, wire strip/crimp, harness routing, riveting, and EOL tests; EOAT/fixtures with compliant tooling and quick‑change.
• Working experience with Robot Programming & OLP/Simulation: Native stacks (URScript, TP/KAREL, RAPID, KRL, INFORM, ACE, AS, VAL3, SPEL+, MELFA BASIC, FD, ORiN); OLP (RoboDK, Visual Components, DELMIA OLP, RobotStudio, ROBOGUIDE, KUKA.Sim, Process Simulate); reach/collision/cycle‑time validation and post‑processors.
• Working experience with PLC/Motion/HMI/SCADA: Rockwell, Siemens, Omron, Schneider, Beckhoff, Mitsubishi; IEC‑61131‑3 logic; motion/VFD; safety PLCs; HMI/SCADA; S88 state modeling.
• Networks/Fieldbus & IIoT: EtherNet/IP, PROFINET, EtherCAT, DeviceNet, Modbus/TCP, POWERLINK; OPC‑UA, MQTT/HiveMQ, Kafka; VLAN, NTP/PTP, OT firewalls.
• Collaborate to work with expert peers inVision & In‑Station AI to commission: Keyence/Cognex/IDS/SICK/RealSense; OCR/label verification, bin‑picking, hole/slot location, projector guidance; OpenCV/Cognex Designer pipelines.
• Working experience with Digital Work Instructions (DWI) & AR based deployment: LightGuide, Arkite, PTC Vuforia; operator guidance, serialization, step traceability, rework routing.
• MES/IIoT/Data Backbone: Apriso/Ortems/eMaint integration; WO/routing/serial/QA mapping; FPY/OEE/SPC dashboards via MQTT/Kafka/OPC‑UA.
• Safety & Compliance: ISO 12100, ISO 10218/TS 15066, ANSI/RIA R15.06, IEC 61508/62061, ISO 13849‑1; risk assessments; LOTO; CE/UL doc packs.
• Industry 4.0 Lab Ownership: Lab architecture, vendor ecosystem, standard cell templates, commissioning checklists, code libraries, PoCs, training.
• Supplier/Vendor & Project Governance: RFQs/specs, ATPs, spares, integrator/OEM management, coding standards, change control, KPI impact."
**Qualifications:**
B.E./B.Tech or M.E./M.Tech in Electrical/Electronics/Mechatronics/Robotics/Industrial Engineering.
8+ years commissioning HMLV/ETO automation (concept→design→build→FAT/SAT→ramp) with multi‑robot and multi‑PLC environments.
**Skills:**
"• Robot OEMs (hands‑on commissioning experience)
Universal Robots (UR), FANUC, ABB, KUKA, Yaskawa Motoman, Omron/TM, Kawasaki, Stäubli, Epson, Mitsubishi, Nachi, Denso.
• Languages: URScript/PolyScope; TP/KAREL; RAPID; KRL; INFORM; ACE; AS; VAL3; SPEL+; MELFA BASIC; FD; ORiN.
Capabilities: TCP/tool/user frames; external axes; force/torque; vision guidance; safe zones; multi‑robot cell balancing; program versioning.
• OLP & Simulation
RoboDK, Visual Components, DELMIA OLP, RobotStudio, ROBOGUIDE, KUKA.Sim, Process Simulate—reach/collision, cycle‑time, buffer sizing, EOAT feasibility, layout/MTM/MOST, post‑processors.
• PLC/Motion/HMI/SCADA
Rockwell, Siemens, Omron, Schneider, Beckhoff, Mitsubishi—IEC‑61131‑3 (ST/LD/FBD/SFC), motion/VFD/servo tuning, safety PLCs, HMI/SCADA, historians, alarm/event models, S88 state machines.
• Networks/Fieldbus & IIoT
EtherNet/IP, PROFINET, EtherCAT, DeviceNet, Modbus/TCP, POWERLINK; safety over bus (CIP Safety/Profisafe); OPC‑UA, MQTT/HiveMQ, Kafka; VLAN, NTP/PTP, OT firewalls.
• Vision & Metrology
Keyence/Cognex/IDS/SICK; barcode/OCR, dimensional checks, bin‑picking, projector alignment; camera/lens/light selection; calibration tooling; accuracy validation.
• EOAT/Fixtures & Pneumatics/Electrical
Pneumatic/electric grippers; compliant tooling; quick‑change; wire strip/crimp heads; screwdrivers/torque tools; panel build standards, EMC/grounding; compressed air design (FRL, flow/pressure), vacuum.
• DWI/AR & Traceability
LightGuide/Arkite/Vuforia; operator guidance; step enforcement; serialization; label compliance; rework routing.
• MES/ERP/PLM Integration
Apriso/Ortems/eMaint + ERP/PLM; object mapping (WO/routing/serial/QA); FPY/OEE and SPC integration; data lineage and audit.
• Safety & Compliance
Risk assessment (PL/SIL), guarding/sensors, LOTO; CE/UL doc sets; factory safety audits.
• Quality/EOL Automation
Automated electrical functional tests, device actuation, SPC; barcode/RFID; dashboards.
• Coding & Toolchains (preferred)
Structured text for PLC, Python for data/vision, Git for version control; CSV/JSON schema for recipes; secure design (IEC 62443 basics)Deep knowledge in electrical and instrumentation design
• Ability to perform system validation and FAT/SAT testing
• Experience with data acquisition and analytics platforms"
"• Self-motivated; Passionate to bring own ideas to applications
• Ability to guide and inspire cross-functional teams
• Networking ability across organization to understand critical business problems
• Clear and effective verbal and written communication with stakeholders
• Strong problem-solving skills for complex automation challenges (DMAIC Certified is preferred)
• Skilled in planning, budgeting, and executing projects on time. Established project management skills while handling multiple projects
• Comfortable working in dynamic environments with evolving technologies
• Ability to document, plan, market, and execute programs
• Vendor negotiation
• Documentation/training discipline
• Cross‑site deployment governance"
The Lead Engineer – Industrial Automation will design, commission, and scale fully automated production solutions for ETO electrical assemblies (switchboards, LV assemblies), covering robotics, PLC/motion controls, vision/AI-guided assembly, digital work instructions, and MES/IIoT integration. The role owns URS→FAT→SAT delivery, creates standard cell templates, and leads Eaton’s Industry 4.0 lab: selecting hardware/software, building demonstrators, publishing commissioning playbooks, and training engineers for repeatable deployments across plants.
"• System Architecture & Commissioning Ownership: Convert URS/SRS to detailed control architecture (cells/lines, safety zoning, networks); author FMEA/PFMEA; define ISA‑S88 state machines; lead design reviews, pre‑FAT, FAT, SAT, ramp‑up, handover.
• Robotics Integration (ETO Assembly & Wiring): Flexible robotic cells for panel/enclosure handling, device insertion, torqueing, label OCR, busbar handling, wire strip/crimp, harness routing, riveting, and EOL tests; EOAT/fixtures with compliant tooling and quick‑change.
• Working experience with Robot Programming & OLP/Simulation: Native stacks (URScript, TP/KAREL, RAPID, KRL, INFORM, ACE, AS, VAL3, SPEL+, MELFA BASIC, FD, ORiN); OLP (RoboDK, Visual Components, DELMIA OLP, RobotStudio, ROBOGUIDE, KUKA.Sim, Process Simulate); reach/collision/cycle‑time validation and post‑processors.
• Working experience with PLC/Motion/HMI/SCADA: Rockwell, Siemens, Omron, Schneider, Beckhoff, Mitsubishi; IEC‑61131‑3 logic; motion/VFD; safety PLCs; HMI/SCADA; S88 state modeling.
• Networks/Fieldbus & IIoT: EtherNet/IP, PROFINET, EtherCAT, DeviceNet, Modbus/TCP, POWERLINK; OPC‑UA, MQTT/HiveMQ, Kafka; VLAN, NTP/PTP, OT firewalls.
• Collaborate to work with expert peers inVision & In‑Station AI to commission: Keyence/Cognex/IDS/SICK/RealSense; OCR/label verification, bin‑picking, hole/slot location, projector guidance; OpenCV/Cognex Designer pipelines.
• Working experience with Digital Work Instructions (DWI) & AR based deployment: LightGuide, Arkite, PTC Vuforia; operator guidance, serialization, step traceability, rework routing.
• MES/IIoT/Data Backbone: Apriso/Ortems/eMaint integration; WO/routing/serial/QA mapping; FPY/OEE/SPC dashboards via MQTT/Kafka/OPC‑UA.
• Safety & Compliance: ISO 12100, ISO 10218/TS 15066, ANSI/RIA R15.06, IEC 61508/62061, ISO 13849‑1; risk assessments; LOTO; CE/UL doc packs.
• Industry 4.0 Lab Ownership: Lab architecture, vendor ecosystem, standard cell templates, commissioning checklists, code libraries, PoCs, training.
• Supplier/Vendor & Project Governance: RFQs/specs, ATPs, spares, integrator/OEM management, coding standards, change control, KPI impact."
**Qualifications:**
B.E./B.Tech or M.E./M.Tech in Electrical/Electronics/Mechatronics/Robotics/Industrial Engineering.
8+ years commissioning HMLV/ETO automation (concept→design→build→FAT/SAT→ramp) with multi‑robot and multi‑PLC environments.
**Skills:**
"• Robot OEMs (hands‑on commissioning experience)
Universal Robots (UR), FANUC, ABB, KUKA, Yaskawa Motoman, Omron/TM, Kawasaki, Stäubli, Epson, Mitsubishi, Nachi, Denso.
• Languages: URScript/PolyScope; TP/KAREL; RAPID; KRL; INFORM; ACE; AS; VAL3; SPEL+; MELFA BASIC; FD; ORiN.
Capabilities: TCP/tool/user frames; external axes; force/torque; vision guidance; safe zones; multi‑robot cell balancing; program versioning.
• OLP & Simulation
RoboDK, Visual Components, DELMIA OLP, RobotStudio, ROBOGUIDE, KUKA.Sim, Process Simulate—reach/collision, cycle‑time, buffer sizing, EOAT feasibility, layout/MTM/MOST, post‑processors.
• PLC/Motion/HMI/SCADA
Rockwell, Siemens, Omron, Schneider, Beckhoff, Mitsubishi—IEC‑61131‑3 (ST/LD/FBD/SFC), motion/VFD/servo tuning, safety PLCs, HMI/SCADA, historians, alarm/event models, S88 state machines.
• Networks/Fieldbus & IIoT
EtherNet/IP, PROFINET, EtherCAT, DeviceNet, Modbus/TCP, POWERLINK; safety over bus (CIP Safety/Profisafe); OPC‑UA, MQTT/HiveMQ, Kafka; VLAN, NTP/PTP, OT firewalls.
• Vision & Metrology
Keyence/Cognex/IDS/SICK; barcode/OCR, dimensional checks, bin‑picking, projector alignment; camera/lens/light selection; calibration tooling; accuracy validation.
• EOAT/Fixtures & Pneumatics/Electrical
Pneumatic/electric grippers; compliant tooling; quick‑change; wire strip/crimp heads; screwdrivers/torque tools; panel build standards, EMC/grounding; compressed air design (FRL, flow/pressure), vacuum.
• DWI/AR & Traceability
LightGuide/Arkite/Vuforia; operator guidance; step enforcement; serialization; label compliance; rework routing.
• MES/ERP/PLM Integration
Apriso/Ortems/eMaint + ERP/PLM; object mapping (WO/routing/serial/QA); FPY/OEE and SPC integration; data lineage and audit.
• Safety & Compliance
Risk assessment (PL/SIL), guarding/sensors, LOTO; CE/UL doc sets; factory safety audits.
• Quality/EOL Automation
Automated electrical functional tests, device actuation, SPC; barcode/RFID; dashboards.
• Coding & Toolchains (preferred)
Structured text for PLC, Python for data/vision, Git for version control; CSV/JSON schema for recipes; secure design (IEC 62443 basics)Deep knowledge in electrical and instrumentation design
• Ability to perform system validation and FAT/SAT testing
• Experience with data acquisition and analytics platforms"
"• Self-motivated; Passionate to bring own ideas to applications
• Ability to guide and inspire cross-functional teams
• Networking ability across organization to understand critical business problems
• Clear and effective verbal and written communication with stakeholders
• Strong problem-solving skills for complex automation challenges (DMAIC Certified is preferred)
• Skilled in planning, budgeting, and executing projects on time. Established project management skills while handling multiple projects
• Comfortable working in dynamic environments with evolving technologies
• Ability to document, plan, market, and execute programs
• Vendor negotiation
• Documentation/training discipline
• Cross‑site deployment governance"
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