Senior Automation Specialist

About Blue Bird Corporation

Blue Bird (NASDAQ: BLBD) is recognized as a technology leader and innovator of school buses since its founding in 1927. Our dedicated team members design, engineer and manufacture school buses with a singular focus on safety, reliability, and durability. School buses carry the most precious cargo in the world – 25 million children twice a day – making them the most trusted mode of student transportation. The company is the proven leader in low- and zero-emission school buses with more than 25,000 propane, natural gas, and electric powered buses sold. Blue Bird is transforming the student transportation industry through cleaner energy solutions.

Job Summary

The Senior Automation Specialist delivers and sustains automated manufacturing equipment and process capability across the equipment lifecycle. This role focuses on equipment performance, process robustness, and reliability to meet safety, quality, throughput, and cost objectives. The specialist leads equipment acceptance activities (FAT/SAT/Run-at-Rate), validates capability targets (e.g., Cp/Cpk, OEE, MTBF/MTTR), and partners with Operations, Maintenance, Quality, Manufacturing Engineering, and suppliers/integrators to implement scalable, maintainable automation solutions.

Essential Duties And Responsibilities

• Equipment & Automation Systems Design, Specify, Program, and Commission Automated Manufacturing Equipment, Including:
• PLC-controlled systems
• Robotics and motion systems
• Vision inspection systems
• Material handling and part tracking solutions
• Build and sustain HMI interfaces for machine control, diagnostics, alarms, and operator interaction.
• Define and validate equipment capability (Cp/Cpk, OEE, MTBF, MTTR) to ensure systems meet production and quality requirements.
• Lead equipment buy-off activities, including FAT, SAT, and Run-at-Rate support.
• Robotics Programming & Integration
• Develop and refine robot programs (online/offline) to support applications such as material handling, assembly, welding, dispensing, and palletizing.
• Optimize robot motion and interactions for cycle time, repeatability, reliability, and safe recovery.
• Integrate robots and vision systems with PLCs, safety circuits, and peripheral equipment; support commissioning and validation activities.
• Process & Manufacturing Capability
• Translate product and process requirements into automation solutions that are repeatable, stable, scalable, and maintainable.
• Develop and validate process windows and settings within automated equipment to ensure consistent output across shifts and lots.
• Identify automation-driven risks and implement mitigation (poka-yoke, interlocks, detection/verification, alarms) to protect quality and safety.
• Support continuous improvement initiatives targeting yield, cycle time, scrap reduction, and labor efficiency.
• Equipment Reliability & Sustainment
• Support start-up, ramp, and high-volume production through hands-on troubleshooting and optimization.
• Partner with Maintenance to develop: Preventive maintenance strategies, Spare parts lists, Technical documentation and training materials, Drive corrective actions for chronic equipment or process issues.
• Support modifications and retrofits driven by process changes, cost reduction, or obsolescence.
• Cross-Functional & Supplier Engagement
• Collaborate with Product Engineering, Manufacturing Engineering, Quality, Operations, and Maintenance throughout equipment development and deployment.
• Manage automation suppliers and integrators for technical scope definition, deliverables, timelines, and performance accountability (as assigned).
• Support PFMEA/DFMEA contributions, control plan development, and quality audits related to automated processes.

Knowledge, Skills And Abilities For Success

• Strong understanding of automated equipment capability and manufacturing process control, including Cp/Cpk, OEE, MTBF, and MTTR.
• Experience supporting or commissioning industrial robots (e.g., FANUC, ABB, KUKA, Yaskawa) and integrating with equipment/process requirements.
• Proficiency troubleshooting control systems and complex electromechanical systems in a production environment.
• Experience integrating or supporting vision systems (e.g., Cognex, Keyence) and automated detection/verification strategies.
• Familiarity with functional safety concepts and applicable standards (ANSI/ISO/OSHA and internal safety requirements).
• Familiarity with Lean Manufacturing and Six Sigma principles; ability to apply structured problem-solving methods.
• Strong systems-level thinking with focus on equipment-process interaction and sustainable countermeasures.
• Clear technical communication with operators, engineers, maintenance teams, and suppliers/integrators; results-oriented mindset.

Basic Education And Experience Required

• 5+ years of experience in industrial automation and programming within a manufacturing environment.
• All candidates must be a U.S. citizen or permanent resident.

PREFERRED EDUCATION AND EXPERIENCE

• Bachelor's degree in Engineering (Mechanical, Electrical, Industrial, Mechatronics, or related).

WE VALUE

• Ability to anticipate and understand customer needs and provide guidance.
• Excellent interpersonal and customer relationship skills to handle difficult and sensitive matters.
• Strong project management skills.
• Exposure to difficult or complex projects a plus.
• Ability to influence stakeholders.
• Effective communication and ability to communicate complex details in a clear manner.
• Flexible workspaces and work hours that help you unleash the best you.
• Working in a collaborative team and balancing the needs of individual stakeholders while delivering corporate objectives.

INCLUDES

• Continued Professional Development
• Benefits including medical, dental and vision insurance, 14 paid holidays, vacation time and 401k matching

WORK CONDITIONS

• Manufacturing environment with exposure to heat, cold and noise.
• Must be able to work as necessary.
• Must be able to work with diverse workforce.
• Weekends and travel as required.

PERFORMANCE CRITERIA

• Able to meet engineering standards and procedures.
• Follow company policy and procedures.
• Successful project completion.
• Must meet established department goals.
• Must work within budgetary boundaries.