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Key Responsibilities and Required Skills for an Industrial Programmer

💰 $75,000 - $130,000

EngineeringManufacturingTechnologyAutomation

🎯 Role Definition

The Industrial Programmer is the technical architect and problem-solver at the heart of modern industrial automation. This role is responsible for the entire lifecycle of control systems that drive efficiency, safety, and productivity on the factory floor. From designing and writing the logic that controls complex machinery to troubleshooting and optimizing performance, the Industrial Programmer ensures that the physical and digital worlds of manufacturing work in perfect harmony. This position requires a unique blend of expertise in electrical engineering, software development, and mechanical systems to translate operational needs into robust, reliable, and intelligent automated solutions.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Junior Controls Technician
  • Electrical Technician / Mechatronics Technician
  • Recent Graduate (Mechatronics, Electrical Engineering)

Advancement To:

  • Senior Controls Engineer or Senior Automation Engineer
  • Automation Project Manager
  • Engineering Manager (Controls & Automation)

Lateral Moves:

  • Process Engineer
  • Manufacturing Engineer
  • Field Service Engineer

Core Responsibilities

Primary Functions

  • Design, develop, and implement robust PLC programs from scratch using structured text, ladder logic, and function block diagrams for complex automated machinery and process control systems.
  • Create and deploy intuitive, user-friendly HMI (Human-Machine Interface) and SCADA (Supervisory Control and Data Acquisition) applications for machine operation, process visualization, and data reporting.
  • Perform advanced on-site and remote troubleshooting to diagnose and resolve complex issues with control systems, including debugging PLC logic, analyzing network traffic, and identifying faulty electrical components to minimize production downtime.
  • Integrate, program, and commission industrial robotic systems (e.g., FANUC, KUKA, ABB) for applications such as material handling, welding, pick-and-place, and automated assembly.
  • Read, interpret, and modify electrical, mechanical, and pneumatic schematics, P&IDs, and technical drawings to understand and troubleshoot integrated systems.
  • Implement and optimize motion control systems by configuring, tuning, and programming servo drives and Variable Frequency Drives (VFDs) to achieve precise positioning, speed, and torque control.
  • Lead the on-site installation, commissioning, and start-up support for new automation equipment and production lines, ensuring systems meet performance criteria before handover to production.
  • Author and maintain detailed technical documentation, including control narratives, functional specifications, I/O lists, operator manuals, and as-built electrical schematics to ensure system knowledge is preserved and transferable.
  • Adhere to and champion industry safety standards (e.g., OSHA, NFPA 79, ISO 13849), conducting risk assessments and implementing safety-rated control functions like E-stops, light curtains, and safety PLCs.
  • Modify, enhance, and maintain existing PLC and HMI code to support engineering changes, add new functionality, or improve overall equipment effectiveness (OEE).
  • Manage the complete lifecycle of small to medium-sized automation projects, from initial concept and requirements gathering through design, testing, and final implementation.
  • Establish and maintain stable industrial communication networks, including EtherNet/IP, PROFINET, Modbus TCP/IP, and DeviceNet, for seamless data flow between devices.
  • Select and specify appropriate automation hardware components, including PLCs, I/O modules, sensors, vision systems, and actuators, based on project requirements, performance, and cost-effectiveness.
  • Provide high-level technical support and structured training to maintenance technicians and machine operators to build their competency in operating and troubleshooting automated systems.
  • Conduct and document comprehensive Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) with clients and internal stakeholders to formally verify system functionality against design specifications.
  • Develop and execute rigorous test plans to validate that control systems are reliable, robust, and meet all functional and performance requirements under various operating conditions.
  • Design and implement data collection and historian systems to capture key process variables, alarms, and events for operational analysis, quality control, and continuous improvement initiatives.

Secondary Functions

  • Support ad-hoc data requests and exploratory data analysis from the production and quality teams.
  • Contribute to the organization's long-term automation strategy, Industry 4.0 roadmap, and technology selection processes.
  • Collaborate with business units, process engineers, and IT to translate high-level data needs into tangible engineering requirements.
  • Participate in sprint planning, daily stand-ups, and other agile ceremonies within the engineering and project teams.
  • Manage source code for all programs using version control software (e.g., Git) to ensure traceability and consistency of changes.
  • Interface control systems with higher-level Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) systems for seamless vertical data integration.

Required Skills & Competencies

Hard Skills (Technical)

  • PLC Programming: Expert proficiency in programming platforms such as Rockwell/Allen-Bradley (Studio 5000, RSLogix 500) and Siemens (TIA Portal, STEP 7).
  • HMI/SCADA Development: Experience developing applications on platforms like FactoryTalk View (ME/SE), WinCC, Aveva/Wonderware, or Ignition.
  • Industrial Robot Programming: Hands-on experience with programming and integrating robots from manufacturers like FANUC, KUKA, ABB, or Yaskawa.
  • Motion Control: Deep understanding of configuring and tuning VFDs, servo motors, and multi-axis motion controllers (e.g., Allen-Bradley Kinetix, Siemens SINAMICS).
  • Industrial Networking: Strong knowledge of industrial communication protocols including EtherNet/IP, PROFINET, Modbus TCP/IP, and DeviceNet.
  • Electrical Schematics: Ability to read, interpret, and create electrical design drawings using AutoCAD Electrical or EPLAN.
  • Safety Systems: Knowledge of implementing machine safety standards and programming safety PLCs (e.g., Allen-Bradley GuardLogix, Siemens Safety Integrated).
  • Database & Scripting: Familiarity with SQL databases for data logging and scripting languages like Python or VBA for automating tasks and generating reports.
  • Vision Systems: Experience integrating and programming machine vision systems (e.g., Cognex, Keyence) for inspection and guidance.
  • Component Specification: Proven ability to select appropriate sensors, actuators, I/O modules, and other control system hardware.

Soft Skills

  • Systematic Problem-Solving: A logical, methodical approach to troubleshooting complex, integrated systems under pressure.
  • Analytical Thinking: The ability to analyze data, processes, and system behavior to identify root causes and opportunities for improvement.
  • Clear Communication: Capable of effectively communicating complex technical concepts to non-technical stakeholders, technicians, and management.
  • Attention to Detail: Meticulous and precise in programming, documentation, and system testing to prevent errors and ensure reliability.
  • Project Management: Ability to manage timelines, resources, and scope for automation projects to ensure on-time and on-budget delivery.
  • Adaptability: Flexible and able to learn new technologies and programming platforms quickly in a rapidly evolving industry.
  • Collaboration: A team-oriented mindset with a history of working effectively with cross-functional teams (mechanical, electrical, IT, and operations).

Education & Experience

Educational Background

Minimum Education:

  • Associate's Degree or a technical diploma in a relevant field. Equivalent military training or extensive, certified trade school experience may be considered.

Preferred Education:

  • Bachelor of Science (B.S.) degree.

Relevant Fields of Study:

  • Electrical Engineering / Electrical Engineering Technology
  • Mechatronics Engineering
  • Automation & Controls Engineering Technology
  • Computer Engineering or Computer Science

Experience Requirements

Typical Experience Range:

  • 3-7 years of direct, hands-on experience programming and troubleshooting PLC, HMI, and robotic systems within a manufacturing, system integration, or industrial automation environment.

Preferred:

  • 5+ years of experience is highly valued, particularly with a demonstrated history of leading automation projects from concept to completion, including commissioning and start-up. Experience in a specific industry (e.g., automotive, food & beverage, pharmaceuticals) may be highly desirable.
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