The Senior Field Service Engineer is responsible for leading and executing complex service, troubleshooting, retrofit, and commissioning activities for automated systems. In addition to hands-on technical execution, this role serves as a technical leader and mentor within the Field Service organization, providing advanced problem-solving, customer-facing leadership, and guidance to junior engineers and technicians.
The Senior Field Service Engineer is expected to independently diagnose and troubleshoot high-complexity electrical, mechanical, robotic, and controls issues, contribute to service strategy and continuous improvement initiatives, and act as a trusted technical advisor to customers and internal teams. This position supports a national customer base; therefore, candidates must be willing and able to travel to the Southeast and other regions as needed based on business demand and resource availability. T his role requires the candidates to be based in Toledo, OH., Detroit, MI., Chicago, IN., Indianapolis, IN., or Greensville, SC to effectively support these service regions.
Core Service Responsibilities:
· Respond promptly and travel to customer sites on short notice to troubleshoot, repair, and restore automated systems.
· Diagnose and troubleshoot issues with automated systems, including hardware and software components.
· Independently diagnose and troubleshoot complex electrical, mechanical, robotic, PLC, HMI, VFD, servo, vision, and peripheral device issues.
· Perform advanced on-site and remote technical support, including root cause analysis and long-term corrective actions.
· Execute scheduled maintenance, preventative maintenance, and system health evaluations.
· Replace, repair, or retrofit faulty components and subsystems to restore or improve system functionality.
· Utilize advanced diagnostic tools, software, and system logs to identify and troubleshoot issues efficiently.
· Provides technical leadership and mentorship to Field Service Engineers and Technicians.
· May serve as lead service engineer on complex or multi-day service engagements.
· Supports onboarding and training of new service team members.
· Provides technical leadership and mentorship to Field Service Engineers and Technicians.
· May serve as lead service engineer on complex or multi-day service engagements.
· Supports onboarding and training of new service team members.
Engineering & Controls Responsibilities:
Perform advanced PLC, HMI, robot, servo, VFD, and vision programming modifications.
· Lead troubleshooting and optimization of legacy automation systems.
· Design and implement electrical machine modifications using 2D CAD software.
· Design and implement mechanical machine modifications using 3D modeling software.
· Prepare Bills of Material (BOMs) for service-related modifications and repairs.
· Support panel build, machine startup, debug, commissioning, FATs, and SATs.
Leadership & Project Support:
· Serve as technical lead throughout service projects, retrofits, and customer support engagements.
· Participate in kickoff meetings, design reviews, project status meetings, FATs, and SATs as the senior technical representative.
· Provide clear technical direction and support to cross-functional teams including Electrical Engineering, Mechanical Engineering, Purchasing, and Assembly.
· Review service findings and provide feedback to Engineering for design improvements and standardization.
· Assist with technical concepting, solution development, and feasibility analysis for service, retrofit, and automation opportunities.
· Support quoting activities by contributing technical scope definition, labor estimates, risk identification, and assumptions/exceptions for complex service work.
· Collaborate with Sales, Applications, and Engineering teams during early customer discussions to help shape viable technical solutions as the senior technical representative.
Customer & Documentation Responsibilities:
· Act as a senior customer-facing technical resource, communicating clearly with customers at all organizational levels.
· Train end-users, maintenance personnel, and customer engineers on system operation, maintenance, and best practices.
· Prepare detailed service reports, documentation packages, and user manuals.
· Accurately record time spent and compare against budgeted hours; document root causes for deviations.
· Maintain updated estimated hours on Functional Plans and service work scopes.
Continuous Improvement & Business Support:
· Identify opportunities for cost reduction, efficiency improvements, and service process enhancements.
· Support development of service standards, best practices, and troubleshooting documentation.
· Assist management with service strategy input, technical roadmaps, and skills development planning.
Travel & Schedule:
· Travel and stay out of town as required, up to 75% annually.
· Work after hours, weekends, and holidays when required to support customer needs.
Required Skills & Abilities:
· Advanced ability to diagnose, repair, and optimize complex automated systems (electrical, mechanical, controls, and robotics).
· Strong proficiency with PLC platforms including Allen-Bradley, Siemens, Omron, and/or Mitsubishi.
· Strong proficiency with HMI platforms including Allen-Bradley, Siemens, Maple, and/or C-More.
· Advanced robot programming and troubleshooting experience with Fanuc, ABB, KUKA, and/or Staubli.
· Experience with servo systems, VFDs, motion control, and vision systems.
• Proficiency with 2D CAD (electrical) and 3D CAD (mechanical) design tools.
· Strong understanding of electrical codes, safety standards, and industry best practices.
· Excellent written and verbal communication skills with the ability to interface directly with customers.
· Strong leadership, mentoring, and coaching abilities.
· Excellent time management, prioritization, and independent decision-making skills.
· Willingness and ability to learn new technologies and support legacy systems.
· Dependable, licensed, and able to operate company vehicles.
· Forklift operation experience preferred.
Education and Experience:
· A.S. in Electrical Engineering, Mechanical Engineering, and/or Mechatronics Engineering (B.S. preferred) and 5 years of experience or a minimum of 8 - 10 years of hands-on automation, controls, robotics, or field service.
· Demonstrated experience leading complex service engagements or automation projects.
· Advanced technical certifications are strongly preferred (robotics, PLCs, safety, or motion control).
