Sr. Automation Engineer

PTA Plastics•Longmont, CO

1d•Onsite

About The Position

The Sr. Automation Engineer leads the development, optimization, and strategic advancement of automation systems to improve the efficiency, scalability, and performance of manufacturing operations. This role serves as a technical leader, driving innovation, mentoring team members, and partnering cross-functionally to implement best-in-class automation solutions.

Requirements

Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Mechatronics Engineering, or related field required.
Extensive hands-on experience in automation, robotics, or manufacturing engineering.
Minimum 7–10+ years of experience in automation, manufacturing engineering, or related field, or equivalent combination of education and experience.
Proven experience leading automation projects and implementing advanced manufacturing solutions.
Strong verbal, written, and interpersonal communication skills.
Ability to present technical concepts and project updates to cross-functional teams and leadership.
Deep expertise in tooling, automation systems, and manufacturing processes.
Advanced experience in fixture design and End of Arm Tooling (EOAT).
Strong hands-on experience with: PLC programming and troubleshooting, Robotics (integration, programming, and optimization), Vision systems and sensors, Pneumatics, hydraulics, and motion control systems.
Strong understanding of electrical systems, including low voltage controls and three-phase power.
Expertise in machine safety standards and risk assessments.
Proficiency in 3D CAD software (e.g., SolidWorks).
Ability to design, interpret, and troubleshoot electrical schematics and mechanical drawings.
Advanced analytical and troubleshooting skills with the ability to solve complex technical challenges.
Strong understanding of systems integration and process optimization.
Working knowledge of industrial networking and automation communication protocols.
Proficiency in Microsoft Office Suite.
Experience with ERP/MRP systems and manufacturing software.
Familiarity with data analysis tools and automation-related software platforms.
Demonstrated ability to lead projects and influence cross-functional teams.
Experience mentoring and developing engineers and technical staff.
Strong collaboration skills with internal teams and external partners.
Ability to stand, walk, and move around the production floor for extended periods.
Capable of lifting and carrying heavy objects weighing up to 50 pounds.
Manual dexterity and hand-eye coordination for handling small tools, machine components, and molds.
Ability to work in a fast-paced environment and adapt to changing priorities.
Comfortable wearing personal protective equipment (PPE) such as safety glasses, gloves, and ear protection.
Occasional bending, kneeling, and reaching to access equipment and perform maintenance tasks.
Good vision and color perception for inspecting parts and identifying any defects or abnormalities.
Ability to work in temperature-controlled environments and withstand exposure to noise levels associated with manufacturing machinery.
Ability to receive, comprehend and utilize required training from OSHA and Company including but not limited to the following: Hazard Communication, Lock Out/Tag Out, First Aid and CPR (optional).

Nice To Haves

Master’s degree in Engineering or related field preferred.
Experience with emerging technologies (e.g., 3D printing, advanced automation, Industry 4.0) preferred.

Responsibilities

Lead the development and execution of advanced manufacturing and assembly strategies across product lines.
Serve as a technical expert and primary point of contact for automation systems, robotics, and process integration.
Partner with Engineering, Manufacturing, Tooling, and Quality to define scalable, robust processes for current and future products.
Drive root cause analysis and resolution of complex production issues; implement sustainable corrective actions.
Lead the introduction and validation of new products, equipment, and automation systems into manufacturing.
Proactively identify and execute continuous improvement initiatives to increase efficiency, reduce cost, and improve quality.
Establish and monitor KPIs for automation performance, downtime, and process capability.
Lead capital equipment justification, specification, and implementation efforts.
Develop and standardize best practices for automation design, programming, and integration.
Provide technical leadership and mentorship to junior engineers and technicians.
Lead mold samplings and ensure comprehensive documentation of: Work instructions (including packaging, fixtures, EOAT, with visual aids as needed) Tooling and process improvements required to meet performance standards.
Design and optimize workstation layouts, automation cells, and product flow for molding and finishing operations.
Oversee creation, validation, and continuous improvement of job books and manufacturing documentation.
Evaluate and improve equipment capability, reliability, and overall equipment effectiveness (OEE).
Lead MRB activities and support resolution of nonconforming product through structured problem-solving.
Own and drive Corrective and Preventive Actions (CAPA) to closure.
Provide leadership in tool design reviews, launch activities, and new product development initiatives.
Manage complex automation and tooling projects, ensuring timelines, budgets, and performance targets are met.
Collaborate with suppliers and subcontractors to improve automation performance, delivery, and quality.
Support quoting and cost estimation activities with advanced process and automation insights.
Champion continuous improvement initiatives and lean manufacturing efforts across the organization.
Perform other duties as assigned.