Job Title: PLC & HMI Developer – Automation Engineer
Job Summary:
We are seeking a highly skilled PLC & HMI Developer with 5–6 years of proven experience in reputed organizations. The ideal candidate should have strong expertise in Mitsubishi and Siemens PLCs & HMIs, hands-on knowledge in SPM (Special Purpose Machine) development, and the ability to integrate with third-party software platforms such as LabVIEW and SCADA.This role requires a proactive automation engineer who has expertise in PLC/HMI design, programming, testing, and commissioning while ensuring robust, reliable, and scalable automation solutions.
Key Responsibilities:
1. PLC, HMI & Automation Development
Design, program, and debug PLC logic for Mitsubishi (GX Works / GX Developer) and Siemens (TIA Portal / Step 7) systems.
Develop intuitive, reliable HMI screens (GT Designer/GT Works, WinCC) with alarms, trends, and operator feedback.
2. Robotics Integration & Control
Program and integrate industrial robots/cobots for tasks such as pick-and-place, assembly, handling, and testing.
Coordinate robot motion logic with PLCs, vision systems, and auxiliary equipment for synchronized operation.
3. SPM (Special Purpose Machine) Development
Architect and implement control systems for custom-built machines, ensuring precise sequencing, safety interlocks, and performance optimization.
Collaborate with mechanical/electrical design to ensure seamless machine-level integration.
4. Vision System Design & Implementation
Specify, integrate, and develop machine vision solutions (e.g., Cognex, Keyence, OpenCV/National Instruments) for inspection, alignment, measurement, and defect detection.
Configure lighting, optics, and image processing workflows to meet throughput and reliability targets.
5. BOM Creation & Lifecycle Management
Develop and maintain detailed Bill of Materials (BOM) for control systems, robotics, and vision subsystems, including part numbers, alternates, lead times, lifecycle status, and sourcing notes.
Conduct component selection balancing cost vs. performance/reliability, including value engineering to reduce total cost of ownership without compromising quality.
Work with procurement to qualify suppliers, manage obsolescence risk, and ensure availability of critical spares.
6. Cost & Quality Ownership
Perform cost analysis for automation solutions; identify high-impact areas for cost reduction (standardization, alternate sourcing, design simplification).
Embed quality considerations into design (MTBF targets, environmental ratings, compliance) and participate in design reviews to preempt failure modes.
Support root-cause analysis and corrective actions for field failures, drive continuous improvement (e.g., reduction in rework/scrap, increased first-pass yield).
7. System Integration & Communication
Integrate automation systems with third-party platforms such as LabVIEW, SCADA/MES, and DAQ systems.
Design and implement communication architectures using Modbus RTU/TCP, Profibus, Profinet, Ethernet/IP, etc.
8. Testing, Commissioning & Support
Lead FAT/SAT, on-site commissioning, and handover activities.
Troubleshoot and resolve complex system-level issues during deployment and production ramp-up.
9. Documentation & Knowledge Transfer
Maintain up-to-date technical documentation: logic descriptions, wiring diagrams, version-controlled programs, BOM revisions, test reports, and operation manuals.
Train junior engineers and maintenance teams on system operation, diagnostics, and best practices.
Required Skills & Competencies:
Technical Automation: Mitsubishi GX Works / GX Developer, Siemens TIA Portal / Step 7, GT Designer, WinCC.
Robotics: Programming/integration experience with industrial robots or cobots; understanding of robot-PLC-vision coordination.
Vision Systems: Hands-on with machine vision hardware/software (e.g., Cognex, Keyence, Boumer) and inspection strategy development.
BOM & Cost Management: Ability to create/maintain BOMs, perform cost vs. quality tradeoffs, value engineer designs, and work with procurement.
Integration: LabVIEW, SCADA/MES interfacing, DAQ integration.
Electrical Design Tools: Familiar with EPLAN software for electrical schematics and panel design.
Protocols: Modbus, Profibus, Profinet, Ethernet/IP.
Analytical Troubleshooting: Field debugging, commissioning experience, failure mode anticipation.
Cross-functional Collaboration: Work with design, procurement, production & Process Engineering Team.
Documentation & Version Control: Rigor in maintaining controlled technical records and change tracking.
Educational Qualification:
B.E. / B.Tech in Electrical / Electronics / Instrumentation / Automation (Preferred)
Certifications in PLC/HMI/SCADA programming will be an advantage
