Automation Process Engineer

Location: USA - Louisville, CO

About the role

The Automation and Manufacturing Engineer develops, implements, maintains, and optimizes automated manufacturing processes. This role leads automation projects, supports new product introductions requiring automation, and improves existing manufacturing systems through robotics, PLCs, machine integration, vision systems, and digital manufacturing technologies. The position collaborates closely with Production, Maintenance, Quality, and Engineering teams to enhance safety, quality, productivity, and cost performance while supporting organizational Vision, Mission, and Values.

Responsibilities

• Design, implement, and optimize automated manufacturing systems.
• Identify opportunities to eliminate manual operations through robotics, vision systems, automated handling, and machine integration.
• Collaborate with equipment suppliers and integrators on automation projects.
• Support maintenance and troubleshooting of PLCs, HMI, servo, and motion control systems.
• Support transition to digital manufacturing and machine connectivity.
• Manage automation projects from concept to implementation using project management principles.
• Train operators and technicians on automated equipment.
• Develop work instructions, troubleshooting guides, and maintenance documentation.
• Provide ongoing technical support to production operations.
• Select new manufacturing processes and introduce new equipment into existing processes.
• Provide technical assistance in implementing new manufacturing technologies.
• Follow existing documentation practices and seek continuous improvements.
• Troubleshoot electrical, mechanical, pneumatic, and automation-related issues.
• Develop business cases and ROI analysis for automation and capital projects.
• Analyze manufacturing processes, cycle times, downtime, scrap, and labor utilization to identify automation and process improvement opportunities.
• Develop equipment specifications, obtain vendor quotations, manage equipment procurement, installation, validation, and production startup.
• Operate under minimal supervision with wide latitude for independent judgment.
• Demonstrate understanding, support, and consistent application of organizational Vision, Mission, and Core Values.
• Other duties as assigned.

Requirements

• Bachelor's degree in Mechanical Engineering, Electrical Engineering, Manufacturing Engineering, Mechatronics Engineering, Automation Engineering, or related field.
• Minimum of 3-5 years of experience implementing automation projects in a manufacturing environment, preferably in CNC machining or plastic injection molding operations.
• Experience with PLC programming, industrial robots and cobots, HMI development, and vision systems.
• Proficiency with SolidWorks or other CAD software.

Preferred Qualifications

• Experience with CNC machining automation.
• Experience with injection molding automation.
• Experience with machine vision inspection systems.
• Experience with cobots.
• Experience with Allen-Bradley PLCs.
• Experience with pneumatic and servo-driven automation systems.
• Experience in a regulated manufacturing environment.

Skills

• Ability to work effectively in a cross-functional team environment with Production, Quality, Supply Chain, and Maintenance.
• Strong analytical and problem-solving skills with the ability to assess situations, identify root causes, and develop practical solutions.
• Excellent written and verbal communication skills.
• Ability to manage multiple priorities and projects simultaneously in a fast-paced manufacturing environment.
• Demonstrated project management, organization, and time management skills.
• Advanced proficiency in Microsoft Excel and ability to utilize data for process improvement and decision-making.
• Strong attention to detail with a focus on accuracy, process control, and follow-through.
• Working knowledge of manufacturing materials, material flows, inventory control, and production requirements.
• Ability to lead and promote continuous improvement initiatives while achieving operational objectives.
• Proven ability to establish priorities, meet deadlines, and deliver results on schedule.
• Ability to analyze production data, identify trends, and implement corrective actions.
• Strong understanding of Lean Manufacturing, waste reduction, and process optimization principles.
• Ability to work independently while collaborating effectively within a team environment.
• Ability to prepare capital expenditure requests, develop project justifications, and present ROI analyses to management.

Key Performance Indicators

• Automation cost savings achieved.
• Manufacturing productivity improvements.
• Labor reduction or redeployment through automation.
• Scrap reduction.
• Downtime reduction.
• Automation project completion versus schedule and budget.
• Equipment uptime and reliability improvements.
• Safety improvements associated with automation initiatives.

Work Environment

• Located in a manufacturing facility requiring prolonged sitting, standing, walking, squatting, twisting, and bending.
• Approximately 50% of time spent on the production floor and 50% in a general office environment.
• Requires lifting up to 50 lbs.

Health and Safety – PPE Requirements

• Safety glasses to be worn at all times when on the production floor.
• Safety shoes to be worn at all times when on the production floor.
• Must wear appropriate PPE for all work activities performed; varies based on work.

Pay

Salary Range: $95,000–120,000 based on experience.