Sr Automation Engineer

Key Responsibilities

1. Lead automation technical work for assembly, ultrasonic welding, decorating, testing, labeling and packaging automation lines for Barbie products, including robotic systems, vision inspection stations, servo positioning systems and customized automatic tooling.
2. Develop control program logic: PLC programming (Siemens / Mitsubishi), HMI configuration, servo & motion control, sensor integration, safety circuit design, robot programming and vision system tuning; carry out on-site commissioning, validation and handover to production and maintenance teams.
3. Drive automation reliability improvement: conduct root cause analysis for recurring automation faults, implement permanent corrective actions, optimize program logic and signal interlock to reduce unplanned downtime, improve OEE and lower reject rate.
4. Support automation capital projects and NPI automation requirements: draft technical specifications, review vendor design proposals, witness FAT, perform SAT, lead site installation, commissioning, risk assessment and process validation for new automation cells.
5. Establish and update automation standards, control SOPs, backup procedures, electrical drawings, spare part lists and troubleshooting guides; build knowledge base for automation systems.
6. Ensure all automation systems comply with Mattel global EH&S, machine safety, LOTO, functional safety and local regulatory requirements; conduct safety review for new automation design and machine modification.
7. Use Lean / TPM / Kaizen tools to launch automation improvement projects, realize labor reduction, cycle time optimization and quality control through automation.
8. Mentor junior automation engineers and technicians, deliver technical training; communicate with global Mattel automation teams and overseas vendors, prepare technical reports and project documents in English.
9. Collaborate with quality team to develop automated test & inspection solutions to meet Barbie toy safety and appearance quality requirements.

Requirements

Education & Experience

• Bachelor’s degree or above in Mechatronics, Automation, Electrical Engineering or related majors
• Minimum 5 years of automation engineering experience in high-volume consumer goods, plastic or toy manufacturing; rich experience in assembly / packaging automation is preferred
• Experience with robotic integration, machine vision or multinational manufacturing environment is a strong plus

Technical Competencies

• Proficient in PLC programming, HMI development, motion control, pneumatics and safety interlock design; familiar with Siemens or Mitsubishi platform
• Hands-on experience with industrial robots (Fanuc / ABB / Epson preferred) and machine vision systems
• Able to read electrical schematics, IO allocation, write control specifications and debug automation systems independently
• Skilled in 8D, 5-Why and other root-cause analysis methods; familiar with FAT/SAT and automation project delivery process
• Basic understanding of injection molding, toy assembly or decorating process is an advantage

Soft Skills & Language

• Business English (written and verbal) for global cross-functional communication
• Strong on-site problem-solving ability, project coordination and cross-team collaboration
• Safety-first awareness, systematic thinking, able to balance urgent breakdown support and long-term project delivery
• Hands-on mindset, good coaching skills, result-oriented