Are you considering or aspiring to a career as an Industrial Automation Engineer or Controls Engineer? Awesome choice. Below, I’ll cover what employers are looking for in an Industrial Controls Engineer, what a typical workday is like, some pros and cons of automation industry jobs, and lastly, what a career in the automation industry might pay. Keep reading for a glimpse inside the life of an Industrial Automation Engineer!
- Entry Requirements
- What Does An Automation Engineer Do Every Day?
- Pros And Cons Of Being An Automation Engineer
- Automation Engineer Salary
- Is A Controls Job Right For You?
For a bit of background, I work for Ford Motor Company as an Automation Engineer (formally, my job title is Engineering Specialist, Controls). My Bachelor’s is actually in Information Technology, with a concentration in Software Development. Luckily, I had industry experience as an Automation Technician that helped me to get in to my current job.
Much of my job focus is on developing and debugging Programmable Logic Controller (PLC) logic and robot programs. Because PLC’s and robots are just fancy computers, I’m often able to use the programming techniques, algorithmic thinking, and knowledge of networks that I learned in my degree program. Virtually all equipment at the plant where I work is on an Ethernet/IP network. Having an understanding of TCP/IP networks is very helpful when troubleshooting communication issues.
With that being said, if you’re interesting in becoming an Industrial Automation Engineer, typical Bachelor’s degrees to pursue might include Electrical Engineering, Industrial Automation, or Mechatronics. Employers often cite a Bachelor’s in a field of study related to industrial automation engineering as a minimum hiring requirement.
Of course, hiring requirements are what the employer would like in the ideal case; there’s likely some wiggle room if you have the skills to do the job. Many technicians or electricians with PLC programming experience are able to become Controls Engineers.
Experience Requirements For Industrial Automation Engineering Jobs
Many employers list experience requirements when posting a job offering for Automation or Controls Engineers. Are you worried about or having trouble moving directly into a Controls position out of school? If so, it may be helpful to first build some industry experience as an Industrial Electrician or Automation Technician.
There are also PLC training courses which can be very valuable in terms of gaining a foundation in PLC programming. Relevant training could possibly help you to get a foot in the door if you do not have experience. In my perception, however, employers would prefer to see one or more years of industry experience programming and debugging PLC’s.
As a side note, I’m using the terms Controls, Controls Engineer, Automation Engineer, and Industrial Automation Engineer interchangeably. Someone in this career field may even be referred to as a “PLC Engineer”.
When looking for jobs, the only thing to be careful of is that the title “Automation Engineer” is now also used in the Software Testing field. Generally, if you see the terms “PLC,” “robot,” or “CNC” mentioned in the job listing, it is an Industrial Automation position and not a Software Test Automation position.
What Does An Automation Engineer Do Every Day?
Of course, the answer to this question depends on the company for which you work and your place in the hierarchy. I can only relate my own experience and that of the other Industrial Automation Engineers that I work with. I’d love to hear any comments from other Automation Controls Engineers. How do your responsibilities differ from my own? I would be happy to add your commentary to this post.
Control and automation engineering is a job of many hats. Most days, you will take on a variety of roles, from project management, to personnel administration, to emergency troubleshooting. In my position, my two primary job functions are breakdown response and Continuous Improvement.
Responding To Breakdowns
The name of the game in industrial automation is production – a lot of production. Companies make money by building as many parts as possible during their employees’ regularly-scheduled work day. Overtime hurts profits. Downtime hurts profits.
Manufacturing companies make money when the line is running and when it’s running fast. Jobs Per Hour, or “JPH”, is a key indicator of the health of a factory. There is, of course, some upper limit to how quickly any given process can occur. As a general rule: the more units you can build in a given time (hence, “Jobs Per Hour”), the better.
In such a fast-paced environment, and with equipment moving back and forth dozens, hundreds, or thousands of times per hour, things break! Cables fail, bearings wear out, sensors wiggle out of alignment; Murphy’s Law is active, big time. When things break, factories have a Maintenance Department that is responsible for figuring out what’s wrong and fixing it – as quickly as possible.
Automation And Control Engineer Roles On Breakdowns
Where I work, the Controls Engineer’s role on breakdowns is somewhere between supervision and high-tier tech support. As a salaried employee, the Controls Engineer is responsible to the company for ensuring that the equipment gets back up and running as quickly as possible. Sometimes, this means fixing the problem at hand. Sometimes, however, it means finding a creative way to work around the problem. For this responsibility, you may need to lead and direct maintenance personnel. You will succeed at this task if you:
- Keep a cool head under pressure
- Become knowledgeable about your facility’s equipment
- Direct others so that they are able to think and perform their best
I wouldn’t describe myself as an introvert, but I’m not the most extroverted person in the world, either. To succeed in breakdown response, I strive to become knowledgeable about as many systems as I can. If I know what to do to fix a problem, I can help to guide the team to success.
Follow-Up After Breakdowns
It’s also the Control and Automation Engineer’s job to follow up after breakdowns. I think of this role as “harvesting information”. It will be your job to figure out the nitty gritty details of what went wrong. Once you understand the problem, you can communicate it to others. This helps your organization to become faster and more knowledgeable. Many breakdowns consist of the same problems, occurring over and over again.
Once your organization knows the cause of a problem, and how to correct it, you can improve your “MTTR”. MTTR, or “Mean Time To Repair”, is a term that describes how long it takes to recover from an issue on average. Reducing MTTR raises your “availability”. Availability is what percentage of your factory’s productive time is spent actually building units. When you raise availability, you often raise JPH – and that means success for your organization.
Filling Your Organization’s Knowledge Gaps
At times, you may be working with equipment that isn’t commonly used or that does not commonly break. A production line might be down, and there may not be anyone around who is deeply knowledgeable. In these cases, the Automation Engineer is often asked to follow up on the problem. You may have to contact the equipment’s manufacturer, if necessary. Once you understand the issue, you may be asked to provide technical write-ups and how-to’s for the factory’s maintenance personnel. Some skill in technical writing can come in handy here.
Another possibility is that you will have to perform a temporary repair to get the line going. In cases like this, you’ll need to come back during scheduled maintenance time to finish the job and restore the equipment to its original state. You will need solid organizational skills to ensure that you are resolving important issues when follow-up is needed.
While breakdowns have the potential to be stressful, they are also sometimes the best teachers. Nothing makes being knowledgeable about a piece of equipment more relevant than when it brings the factory to a halt and no one seems to know how to fix it.
No one begins a career in Controls knowing everything. When you work in automation controls engineering, every day should be an opportunity to learn more about the equipment, network, protocols, and infrastructure with which you’re working. You will greatly sharpen your skills and knowledge as a Controls Engineer by following up on the breakdowns.
Breakdowns are emergent events (they just happen all of a sudden). When the factory stops making parts, it’s “all hands on deck” to get things moving again. While breakdowns are the “event-driven” part of the job, my “default state” is working on Continuous Improvement projects.
Continuous Improvement is exactly what it sounds like; it is a practice and mindset of continually boosting production capabilities. This is done by working to improve safety, quality, cost, JPH, MTBF, MTTR*, or sometimes just making things easier for the people who supply and repair the automation lines.
*JPH, MTBF, and MTTR are metrics that summarize the productivity of equipment in an automated factory. JPH, or “Jobs Per Hour,” is simply how many units you are building per hour. As a general rule, the more, the better! Mean Time Between Failure is how often, on average, you are able to use a piece of equipment before it breaks down. Mean Time To Repair, explained above, is how long, on average, it takes you to get the equipment back up and running when it does break.
Factories come in all shapes and sizes, but for me at Ford’s Super Duty Body shop, the factory is enormous. There are dozens of lines of automation just on my side of the shop, with each unit travelling more than a mile in its journey to become a truck! Continuous Improvement is all of the little changes and improvements made throughout the entire shop. These changes contribute to a gradual betterment of production, repair, and ease of use.
As an industrial automation engineer, Continuous Improvement is a focal point of my job. Luckily for me, this is a part of my job that I very much enjoy. As I’ll describe below, Continuous Improvement is a chance to develop solutions to my organization’s problems – and then make those solutions come to life.
How Do You Perform Continuous Improvement?
Continuous Improvement is what I find most rewarding, as the task is essentially this:
- Identify a problem that, if fixed, would improve production or repair in some way
- Come up with a way that you think you can fix it
- Research and purchase the equipment, components, sensors, etc. that you would need to make it happen
- Wait for the parts to come in and then work with other people in the factory to implement your solution
- Stand back and marvel at the results!
It’s pretty cool to know that you’ve personally organized improvements that subtly alter the manufacturing process for every Super Duty built in America. Projects come in all shapes and sizes.. I’ve worked on projects that took only a few hours, such as adding lights to show operators when to load parts, and I’ve worked improvements that took coordinated efforts during scheduled downtime over weeks, including a modernization project (upgrading the capabilities of older equipment by adding modern processors and interfaces).
If you want to become an Industrial Automation Engineer, it will sure be helpful if you enjoy this kind of work. Your organization will have issues that it needs to solve through automation engineering – and you’ll be the one doing the engineering. As I mention above, Continuous Improvement is a part of my job that I love. I get to design and implement solutions, and then see those solutions come to life in front of me.
Continuous Improvement In Industrial Automation Engineering
At the time of this writing, I have a project active to automate the shutdown of my side of the shop at the end of each shift – a task that is currently handled manually on each automation line by Production Supervisors. If everything goes my way, I’ll be taking a process that currently involves about two dozen people throughout the shop placing holds on their lines at certain times, and consolidating the same functionality into a single interface on which the Production Manager can stop the lines however they like for the next shift.
For this project, I will develop new PLC logic, create new PanelView screens, and work with other smart, engaged people. Together, we’ll implement and debug the solution until it’s working flawlessly. Personally, I love to solve puzzles and figure out how things work. If you are that type of person as well, you were made for this part of the job.
Succeeding At Continuous Improvement
Success in executing Continuous Improvement will require many of the same skills that you will need when responding to breakdowns. You’ll need to track your projects and purchases. Further, you’ll need to share your vision with others and organize their efforts in completing the work.
Additionally, you may need to justify your purchases to your manager! You’ll need good judgment for what will help the shop and can be done affordably. You will need to know when to defend your ideas, and when to accept rejection gracefully, if appropriate.
You need to be able to approach things somewhat scientifically. It’s important to strive to understand the behavior of the systems that you’re working with to the greatest extent possible, given your available time, so that you can develop a solution that will function as you expect.
As a final note, Continuous Improvement is another excellent opportunity to acquire new and hone existing skills, as you won’t typically be under the pressure of the breakdown environment. When you’re doing development (writing new logic or developing new screens), it will often be in an offline, scheduled downtime type situation. This means you’ll have some room to breathe and figure out how to make things work the way you need them to work. You can play around with new equipment or software and gain experience and skills. You can then bring your new knowledge to future projects – and can call upon it at future breakdowns.
Pros And Cons Of Being An Automation Engineer
While I love my job, every position has some good and some bad. I want to give you an honest sense of what I see as the pros and cons of a career in Industrial Automation.
Industrial Automation Engineering Pros:
- Technically Challenging – I love learning and striving for mastery of new systems. If you’re like me, it’s awesome to be surrounded every day by a fortress of high-tech equipment. It’s your job to become the expert!
- Pride – My grandfather turned 100 the year that I was hired into my current job. I was incredibly proud to tell him that I would be working for Ford Motor Company as an Automation Engineer
- Pay – Many Controls positions should easily reach six figures. This is particularly true if a lot of travel and overtime are involved
- Benefits – If you’re hiring into a position as an Automation Engineer, chances are that it’s with an established company. You can likely expect a decent insurance and vacation package
- Being a Part of Something – My work in automation has taken me to three countries (my short time in Germany was awesome). I’ve been to awesome major facilities including Ford and Tesla plants. Become a skilled Controls Engineer, and you could work for some of the biggest, most high-tech manufacturers on Earth
Cons Of Being An Industrial Automation Engineer:
- Long Hours – I have worked 8’s, 10’s, and 12’s for Ford. I work 12-hour shifts on my current schedule, and have worked 12’s throughout most of my other experience in the industry
- Rotating Shifts – Depending on the company and its seniority policies, you could be stuck periodically working a shift that you don’t like (night shift, weekends, etc.). In some organizations, you might be stuck on a shift you don’t like until someone leaves their position or the company
- Travel – Depending on the position, extensive travel may be required. This can be very stressful for families. The flip side to this is that you will often be paid more while travelling. So, travel might be a pro, depending on your personal situation
- Labor Relations – Speaking as a salaried employee in a union shop, your success may hinge on your ability to elicit the best out of others. If your shop operates under a union contract, you might also need to tread carefully in regards to what work you can and cannot perform on operational equipment
- Stress – When the line is down, the company is losing money. People will be looking to you to get everything back up and running
Weird Schedules Could Be Good Or Bad
Let me offer another point of view in regards to my schedule: while the 12’s are long days, consider that the average person working a nine-to-five job works 10 days out of every 14. Nine-to-five employees work M-F, then off two days, then M-F, then off two, and so on.
Because I work 12’s, I only work 7 days out of every 14. I’d try to explain my schedule, but it’s much easier to just show you. I work the green days on this calendar:
Now, this looks a bit strange and horrible at first, but now consider:
- I have 4 days off in a row every other week
- Every other week, I only have a 2-day work week
- If I take 2 days of vacation on my 2-day work week, I am off of work for 9 days
I’ve only ever seen this schedule implemented at Ford, but my point in mentioning this is that in manufacturing, there may be multiple options for you as far as what shift you work. You may be able to find something that really works well for your family and lifestyle.
Automation Engineer Salary – Let’s Talk Turkey
So, what can you expect in terms of salary as an Industrial Automation Engineer? Controls Engineering (again, I’m using the terms “controls” and “industrial automation” interchangeably) is a demanding field requiring solid technical, organizational, and people skills. Automation Engineers can expect to earn a decent income.
Unfortunately, the Bureau of Labor Statistics does not have a listing for “Industrial Automation Engineer,” “Controls Engineer,” or “Automation Engineer.” Here are the average salaries listed on various career and industry sites for “Controls Engineer” or “Electrical Controls Engineer” (this information last updated 06 Jun 2019):
Average Controls Engineer Salaries
|Salary.com (Engineer I)||$70,080|
|Salary.com (Engineer II)||$87,891|
|Salary.com (Engineer III)||$105,619|
To me, the biggest question you have to ask yourself is whether you like solving problems and learning about new equipment. If your interests include electronics and programming, and you’re the type of person who has to read and tinker until you understand what you’re doing, then you would do well as an Automation Engineer. You can probably fake it till you make it if you’re in it for the money, but the engineers I know who are very successful are people who gobble up as much knowledge as they can at every turn, and are regarded as world-class experts in their specialties.
Are you currently applying for a position as an Automation Engineer? Are you still in college, considering possible career paths for your future? Let me know where you’re at in the comments below – I’d be happy to provide any insight that I can, and I’d love to hear from other engineers in regards to their own experiences.
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