Automation and Maintenance Engineer

thyssenkrupp is an international industrial and technology group with more than 93,000 employees. In the fiscal year 2024/2025, the company generated sales of around €33 billion in 48 countries. Its business activities are bundled in five segments: Automotive Technology, Decarbon Technologies, Materials Services, Steel Europe and Marine Systems. With extensive technological know-how, outstanding engineering competence and a high level of innovative strength, the group develops solutions for the challenges of the future, especially in climate protection and energy transition, digital transformation in industry and mobility of the future.

At Berco, we produce mission-critical undercarriages for mining, construction, forestry and agriculture machinery. Together with our customers, we create long-lasting solutions by combining know-how in design, forging, heat treatment, machining and assembling. We provide undercarriage components to OEMs (Original Equipment Manufacturers) for the first fit of the machines as well as the service parts to OEMs and to the independent Aftermarket.

About the Role

The Automation Projects & Maintenance Engineer reports to the PLC Production Engineering Manager and is responsible for ensuring the reliability, performance, and continuous improvement of industrial and automated equipment at Berco of America WI plant. This role combines advanced diagnostic expertise with automation and control systems engineering to support stable, efficient, and high-performing operations. The position leads troubleshooting and resolution of production line issues, including electrical, mechanical, pneumatic, electronic, and calibration systems, ensuring rapid response to minimize downtime and maintain operational continuity.

Responsibilities

• Ensure proper functionality of programming in automated lines.
• Manage and resolve production line downtime events.
• Analyze data, identify bottlenecks, and optimize workflows to improve OEE.
• Manage preventive maintenance improvements and collaborate with maintenance to develop PM programs.
• Handle quick maintenance repairs (e.g., change sensor, calibrate sensor).
• Integrate new automation technology with existing production lines.
• PLC Allen Bradley and Siemens programming with solid knowledge of Studio 5000 and TIA Portal.
• TTP and PMC Fanuc programming.
• Ensure routine inspections, services, and repairs in the automated lines.
• Diagnose electrical, mechanical, and software errors in automation systems.
• Monitor and improve the performance of automatic lines.
• Develop new PLC programs for existing and future lines.
• Improve automatic lines process capability indices.
• Attend monthly safety training.
• Provide emergency breakdown support to production lines.

Standards of Performance

• Maximizing equipment run time and reducing unplanned stops.
• Hands-on troubleshooting and maintenance.
• PLC programming and design with Studio 5000 & Simatic S7.
• Standard computer and industrial networks knowledge.
• Mechanical and electrical cross-function in automation.
• Safety compliance.

Essential Functions

• Proficient in English language.
• Ability to view priorities in the long term.
• Ability to work independently as well as with a team.

Requirements

Education/Credentials/Certifications

• Bachelor's in computer science or engineering or related field.

Experience

• Minimum 5 years in Automation/Controls Engineering, Maintenance, or PLC programming.

Knowledge, Skills, & Abilities

• Knowledge of Allen Bradley PLC (Studio 5000).
• Knowledge of S7 TIA Portal.
• Knowledge of operating, programming, and maintaining FANUC industrial robots and CNC machines.
• Knowledge of understanding electrical, electronic, pneumatic, hydraulic schematics.
• Knowledge and understanding of mechanical drawings.
• Knowledge of industrial communication protocols.
• Strong diagnostic abilities to identify and resolve issues in automation systems.
• Comprehensive data analysis (real-time and historical).
• Detail-oriented.
• Able to anticipate future issues.
• Able to make quick connections between events.
• Excellent written and oral language ability.
• Excellent reasoning and problem-solving ability.
• Excellent interpersonal skills.
• Adaptability.
• Ability to multi-task.
• Ability to cope with changes.