Staff Controls, Automation & Mechatronics Engineer

ZT Systems•Secaucus, NJ

About The Position

The Staff Controls, Automation & Mechatronics Engineer will be at the forefront of designing and implementing advanced automation solutions that drive efficiency, scalability, and quality in our server manufacturing operations. This role requires a strong foundation in Controls and mechatronics engineering, combining mechanical, electrical, and software systems to develop integrated automation solutions. They will leverage mechatronics principles to enhance system performance, reliability, and scalability while collaborating across disciplines to support rapid deployment and continuous improvement.

Requirements

Advanced degree in Engineering, Computer Science, Data Science, or a related field.
8+ years of experience in high-volume, high-complexity manufacturing.
Proficiency with data-driven tools such as Minitab, JMP, Python, R, SQL (or equivalent) to analyze and interpret large, complex datasets.
Track record of driving measurable improvements in yield, reliability, or process robustness.
Background in electronics assembly, PCBA, servers, or other high-reliability industries (e.g., aerospace, medical devices, automotive, semiconductor etc.).
Proficiency in CAD tools (SolidWorks, AutoCAD) and industrial automation platforms (Siemens, Allen-Bradley, etc.).
Controls Engineering Skills: Advanced proficiency in PLC programming (Codesys, Siemens, Beckhoff…), HMI/SCADA development, Motion control (servo, stepper systems), Designing and tuning: PID loops, Multi-axis control systems, High-speed machine control.
Automation Systems Design, commissioning, and optimization of: Automated production lines, Robotic cells, Automated test equipment, Material handling & conveyance systems, Industrial protocols (EtherCAT, Ethernet/IP, ProfiNet, Modbus TCP), Control architectures & safety systems.
Mechanical & Mechatronics Systems: Strong mechanical understanding: actuators, sensors, power transmission, machine design.
Experience integrating: Robotics (Fanuc, Kuka, ABB, UR), Pneumatics & hydraulics, Vision systems (Cognex, Keyence, OpenCV), Instrumentation & measurement systems.
Software & Scripting: Python (automation, data logging, test scripts), C/C++ (embedded systems), MATLAB/Simulink (controls modeling), LabVIEW (optional but valued).

Nice To Haves

Exposure to or knowledge of AI/ML toolsets for statistical problem solving, predictive analytics, or anomaly detection.
MBA or exposure to business, finance or economics is advantageous.

Responsibilities

Contribute to transformation initiatives, helping set new standards for how ZT approaches manufacturing risk analysis, quality, and continuous improvement.
Define and implement new systems, processes, or frameworks that support the smart factory vision, including automation, metrology, advanced inspection and testing, and predictive analytics.
Support NPI (New Product Introduction) by developing scalable automation strategies aligned with product roadmaps.
Design and implement automated assembly and test equipment for server components, including PCBs, power modules, and cooling systems.
Collaborate with cross-functional teams to ensure Design for Manufacturability (DFM) and Design for Automation (DFA) Principals are embedded in new product designs.
Translate DFM and PFMEA outputs into actionable process controls, ensuring proactive prevention of variation rather than reactive correction.
Develop and optimize mechatronic systems integrating robotics, sensors, actuators, PLCs, vision systems, motion control and software.
Leverage deep, data-rich environments and tools to generate insights and drive continuous improvement initiatives focused on yield, reliability, cycle time, and throughput.
Work with equipment vendors to specify, validate, and install automation solutions for medium to high-volume production.
Apply manufacturing techniques such as precision fastening, soldering, adhesive bonding, and vision-based inspection.
Lead tool qualification, process documentation, and operator training for new equipment.
Use data-driven methods (e.g., SPC, FMEA, DOE) to troubleshoot and enhance manufacturing performance.
Analyze production workflows to identify automation opportunities & optimize cycle times, throughput, and reliability of automated systems.
Implement automated inspection and testing systems to ensure product quality.
Maintain compliance with safety, environmental, and industry standards.
Create detailed documentation for automated systems, including SOPs and training materials.
Provide technical support and training to production teams.

Benefits

Competitive base salary
Performance-based annual bonus eligibility
401(k) retirement savings plan
Tuition reimbursement for eligible education programs
Comprehensive medical, dental, and vision coverage with access to leading providers
Mental health resources and employee wellness support programs
Company-paid life and disability insurance
Paid time off (PTO) and company-paid holidays
Parental leave and family care support programs
Structured training programs and on-the-job learning opportunities
Matching gifts and volunteer programs to support causes you care about