Key Responsibilities

Projects

- Validate RFQ – Coordinate for Installation & Commissioning of automation systems in Paint/BIW projects
- Solution development & validation in discussion with suppliers to secure Project deliverables
- Coordinate with vendors , Project , Safety & Maintenance team during project phase
- Ensure equipment installation, commissioning & prove out as per the standard in brown field project
- Provide feedback during engineering phase of the project to vendors and ensure necessary controls are in place for Safety, Quality, Delivery, Cost, Workplace, People(SQDCEP) of the process

PLC & Automation System Management

- Handle operation, maintenance, and troubleshooting of PLCs, HMIs, SCADA, and field communication networks (PROFIBUS, PROFINET, Ethernet/IP).
- Maintain and modify logic for PLC’s (Siemens S7-(phone hidden)/1500, Allen Bradley ControlLogix, or Mitsubishi PLCs etc)
- Develop, modify, and validate interlocks, safety logics, and process control sequences for both BIW and Paint Shop.
- Perform program backups, documentation, and version control as per plant standards.
- Interface PLCs with robots, drives, and higher-level control systems (MES, SCADA).
- Interface with IT as a key user & train other users

Robotics & Mechatronic Systems

- Maintain and troubleshoot industrial robots in BIW (spot welding, MIG welding, material handling) and Paint Shop (painting, sealing, and sanding robots).
- Work with robot controllers for programming and calibration (Fanuc, ABB, KUKA, or Yaskawa etc.)
- Monitor robot paths, process parameters, and communication with PLCs.
- Support robot re-teaching, parameter tuning, and error recovery for cycle optimization.

BIW (Body-in-White) Systems

- Maintain automation systems in spot welding, framing, and sealer application lines etc.
- Troubleshoot electrical and control systems for welding controllers (Aro, Bosch, Medar,



OBARA etc), servo guns, and motion controllers.
- Monitor conveyor control systems, lifters, turntables, and positioning devices.
- Ensure accuracy of interlocks, sensors, limit switches, and field I/O modules.
- Implement process improvements to reduce weld cycle time and enhance equipment reliability.

Paint Shop Systems

- Maintain PLCs, HMIs, and automation for :

1. 1. Pretreatment (PT) & Electrodeposition (ED)
2. Paint booths, ovens, and circulation systems
3. Conveyors and air handling units (AHUs)
4. Robotic painting and sealing systems

- Monitor and control temperature, pressure, humidity, and flow through instrumentation systems.
- Support energy optimization in paint booths, curing ovens, and exhaust fans.

Control Panel & Electrical Maintenance

- Maintain and troubleshoot MCCs, control panels, and field junction boxes.
- Perform load analysis, insulation resistance checks, and earth resistance testing.
- Maintain and test safety relays, interlocks, and E-stops as per EHS standards.
- Ensure compliance with IEC, IS, and EHS safety standards.

Data Monitoring & Continuous Improvement

- Utilize SCADA, MES, and data acquisition systems for monitoring downtime and process parameters.
- Perform Root Cause Analysis (RCA) for recurring automation faults and implement corrective actions.
- Support TPM, Kaizen, and Lean initiatives to improve equipment reliability and reduce energy consumption.
- Develop dashboards for cycle time monitoring, robot downtime, and alarm history analysis.

Documentation & Audit Compliance

- Maintain updated electrical schematics, control logic diagrams, and automation documentation.
- Keep preventive maintenance and calibration records for all automation systems.
- Ensure compliance with IATF 16949, ISO 14001, and ISO 45001 requirements.
- Participate in internal and external audits (EHS, TPM, IATF) with relevant data and reports.

📌 PLC & Automation Engineer - BIW & Paint Shop (Bengaluru)
🏢 Volvo Group
📍 Bengaluru