Automation Controls Technician

ZT Systems•Secaucus, NJ

About The Position

The Automation Controls Technician (PLC) serves on ZT Systems’ Advanced Automation Infrastructure team and supports automated assembly operations. This role is responsible for keeping equipment controls reliable and responding to automation stoppages by troubleshooting PLCs, HMIs, sensors, I/O, networks, and safety systems. The technician also works with OEMs, system integrators, and engineering teams to improve systems and prevent recurring failures. The position maintains controlled programs, configurations, backups, network documentation, and equipment recovery files; develops a critical controls spare-parts strategy and preventive maintenance program; and analyzes downtime and failure data to improve reliability. The technician also cross-trains and provides backup support for automated mechanical systems. The typical base salary is expected to be $35 per hour. The final base salary is determined individually based on experience, skills, knowledge, education, and certifications. Other rewards may include a bonus, paid time off, a 401(k) match, tuition reimbursement, and wellbeing resources. ZT Systems describes its work environment as fast-paced and offers hands-on experience, collaboration, training, and on-the-job learning.

Requirements

Trade school certification in a technical field, at minimum.
At least 6 years of practical experience in an automated manufacturing environment.
Deep expertise in industrial automation controls, including PLCs, HMIs, I/O systems, sensors, safety circuits, industrial networks, and SMEMA machine sequencing.
Ability to troubleshoot complex controls failures from the field device through the PLC, network, HMI, and machine sequence without relying solely on OEM support.
Experience reading and interpreting electrical schematics, control panel drawings, I/O lists, PLC logic, network architecture, and machine documentation.
Experience with PLC programming (Festo / CodeSys / Structured Text), HMI configuration, controls integration, industrial Ethernet, sensors, and safety systems in automated manufacturing.
Ability to establish and maintain controlled PLC/HMI backups, configuration records, software versions, and machine recovery documentation.
Ability to perform root-cause analysis on recurring controls failures and implement improvements that increase equipment reliability and reduce downtime.
Strong technical judgment and change-control discipline, including the ability to make repairs independently and recognize when engineering, OEM, or system-integrator escalation is needed.
Experience with Microsoft Office tools, including Outlook, Excel, and Word.
Strong verbal and written communication skills.

Responsibilities

Own PLC, HMI, electrical controls, sensors, I/O, and automation networks supporting production equipment.
Troubleshoot controls issues across field devices, I/O, PLC logic, networks, HMIs, and machine sequences to restore equipment.
Maintain controlled PLC/HMI programs, configurations, backups, network documentation, and machine recovery files.
Develop and execute a critical controls spare-parts strategy and preventive maintenance program based on equipment criticality and downtime exposure.
Partner with OEMs, system integrators, and engineering teams to resolve controls issues, implement improvements, and eliminate recurring failures.
Analyze controls-related downtime and failure data to identify root causes and improve equipment reliability and automation performance.
Cross-train and provide backup support for automated mechanical systems to build team knowledge and reduce single points of knowledge.