Job Tittle: Maintenance Lead – PLC, Automation &amp; RoboticsLocation: BangaloreIndustry: BESS / EV / Lithium-ion Battery / Automated ManufacturingExperience: 12+ YearsQualification: B.E./B.Tech. in Electrical / Electronics / Instrumentation / Mechatronics <h2>Role Overview</h2>We are looking for an experienced Maintenance Lead – PLC, Automation &amp; Robotics to lead automation engineering, maintenance, troubleshooting, commissioning, and optimization of highly automated BESS assembly and manufacturing lines.The ideal candidate should have strong hands-on expertise in PLC programming, industrial robotics, servo and motion systems, industrial communication networks, laser welding, pneumatics, MES, HMI, and production automation. <h2>Key Responsibilities</h2><ul><li>Lead PLC programming, troubleshooting, logic optimization, commissioning, and maintenance using Keyence KV8000, Siemens TIA Portal, Mitsubishi GX Works 2/3, and Omron Sysmac Studio.</li><li>Manage PLC-HMI communication, data logging, machine integration, and production monitoring systems.</li><li>Handle FAT/SAT, machine commissioning, validation, and automation system integration.</li><li>Configure, tune, and troubleshoot servo drives and motion-control systems, including Inovance and other precision motion platforms.</li><li>Lead operation, programming, path teaching, commissioning, and maintenance of KUKA, Yamaha, and FANUC robots.</li><li>Troubleshoot robotic controllers, servo systems, mechanical issues, communication failures, and programming-related problems.</li><li>Optimize robotic cycle time and overall equipment performance.</li><li>Manage and troubleshoot industrial communication networks including EtherCAT, PROFINET, CC-Link, and EtherNet/IP.</li><li>Maintain and troubleshoot distributed I/O systems including Beckhoff, SMC, Elco, and other automation platforms.</li><li>Lead preventive and breakdown maintenance of laser welding systems, including IPG Photonics, Max Photonics, and Carman Haas welding heads/optics.</li><li>Ensure proper alignment, maintenance, and performance of laser and optical systems used in BESS manufacturing.</li><li>Manage SMC and Airtac pneumatic systems, including cylinders, solenoid valves, FRLs, manifolds, and vacuum systems.</li><li>Optimize pneumatic and vacuum systems to improve equipment reliability and reduce compressed-air consumption.</li><li>Drive improvements in OEE, equipment availability, cycle time, MTBF, and MTTR while reducing recurring breakdowns.</li><li>Plan manpower deployment for breakdown maintenance, preventive maintenance, commissioning, and improvement activities.</li><li>Lead Root Cause Analysis (RCA), CAPA, and continuous improvement initiatives for chronic automation and equipment failures.</li><li>Manage critical automation spares, inventory, AMC/service requirements, and vendor relationships.</li></ul> <h2>Candidate Profile</h2><ul><li>12+ years of experience in automated manufacturing environments.</li><li>Strong hands-on experience in PLC, robotics, automation maintenance, and troubleshooting.</li><li>Experience in BESS, EV, lithium-ion battery manufacturing, or other highly automated production environments will be preferred.</li><li>Strong understanding of preventive and breakdown maintenance, RCA, CAPA, OEE, MTBF, and MTTR.</li><li>Ability to lead maintenance teams and coordinate effectively with production, engineering, OEMs, and external vendors.</li><li>Strong problem-solving and troubleshooting skills with a hands-on approach</li></ul>