Sr. Programmer Analyst

AAM - American Axle & Manufacturing•Gallatin, TN

2d•Hybrid

About The Position

The Sr. Programmer Analyst (Automation Controls Engineer / PLC/VFD Programmer) is a specialized role in industrial automation, focusing on designing, developing, implementing, and maintaining control systems for manufacturing, process industries, utilities, and machinery.

Requirements

Bachelor’s degree in Electrical Engineering, Automation, Computer Science, Mechanical Engineering, or a related field (or equivalent vocational/technical training + experience).
Typically 3–7+ years in PLC programming and industrial automation.
Strong problem-solving, analytical, and troubleshooting abilities; communication and teamwork skills; attention to detail; willingness to travel and work in industrial environments.
Proficiency in major PLC platforms (e.g., Allen-Bradley/Rockwell Studio 5000/ControlLogix, Siemens TIA Portal/S7, Schneider, Beckhoff TwinCAT, Omron, Mitsubishi).
Experience with VFDs (e.g., parameter configuration, tuning, integration with PLCs for brands like Allen-Bradley, Danfoss, Yaskawa, Siemens Sinamics).
Knowledge of HMI/SCADA development (e.g., FactoryTalk View, Ignition, WinCC).
Understanding of electrical schematics, motor controls, instrumentation, networking, and safety systems.

Responsibilities

Design and Develop Programs: Create PLC logic using languages such as Ladder Logic (LAD), Function Block Diagram (FBD), Structured Text (ST), and Sequential Function Chart (SFC) per IEC 61131-3 standards. Program and tune VFDs for motor speed, torque, and control applications.
System Integration: Integrate PLCs with HMIs (Human-Machine Interfaces), SCADA systems, sensors, actuators, servo drives, robotics, and other automation hardware. Configure industrial networks and protocols (e.g., EtherNet/IP, Modbus TCP, Profinet, OPC UA).
Testing and Commissioning: Perform factory acceptance testing (FAT), site acceptance testing (SAT), functional testing, and on-site commissioning. Troubleshoot hardware/software issues in PLCs, VFDs, control panels, and I/O systems to minimize downtime.
Maintenance and Optimization: Monitor, debug, modify, and upgrade existing programs. Implement process improvements, PID control loops, safety circuits, and efficiency enhancements. Back up programs and maintain documentation.
Documentation and Collaboration: Develop schematics, electrical drawings, P&IDs, and technical documentation. Work with cross-functional teams (engineering, maintenance, operations) and provide training/support to end-users. Ensure compliance with safety standards (e.g., NFPA 79, UL 508A) and regulations.
Troubleshooting and Support: Diagnose issues with motors, VFDs, instrumentation, and control logic. Use diagnostic tools and perform root-cause analysis.
Writes, tests, troubleshoots, and optimizes programs for Programmable Logic Controllers (PLCs) and integrates Variable Frequency Drives (VFDs) to control motors, machinery, and automated processes.
Ensure systems run safely, efficiently, and reliably, often collaborating with electrical/mechanical engineers, technicians, and operations teams.
Limited travel for commissioning, on-site troubleshooting, and support.
Project & Operational Support as needed.