Role Overview:
This is a critical “make-or-break” role responsible for connecting all factory machines—modern and legacy—to a centralized monitoring system. The engineer will determine, design, and implement the best method to extract machine data, whether through existing industrial protocols or custom-built sensor retrofits. The role combines industrial automation, IoT, embedded systems, and edge computing to enable real-time monitoring, analytics, and predictive maintenance across the plant.
Key Responsibilities
Machine Connectivity & Integration
* Audit all active machines to assess data availability and optimal connectivity approach.* Integrate modern machines using industrial communication protocols such as OPC-UA, Modbus, Profinet, APIs, and JDF/CIP4 (Heidelberg).* Design and implement connectivity solutions for both automated and manual machines.
Legacy Machine Retrofit Solutions
* Design sensor-based retrofits for machines without controllers or data ports.* Implement production counters, current/power sensors, vibration sensors, and optical/proximity sensors to capture:
* Machine run status * Production count * Basic machine health metrics
Embedded Systems & Hardware Development
* Design and develop embedded systems using ESP32, STM32, Raspberry Pi, or industrial MCUs.* Develop firmware (C/C++ / Micro Python) for sensor data acquisition and communication.* Design PCBs (basic level) and rugged enclosures suitable for industrial environments.* Ensure safe power design, isolation, and industrial-grade reliability.
IoT & Edge Computing
* Set up edge gateways for machine data collection.* Implement MQTT-based data pipelines from machines to cloud/platform.* Integrate REST APIs and other IoT communication protocols.* Work with platforms for real-time monitoring, data logging, and analytics.
Automation & Control Systems
* Program, troubleshoot, and integrate PLCs (Siemens, Allen-Bradley, Schneider, Delta).* Work with SCADA systems and industrial control networks.* Integrate sensors, actuators, and industrial devices into automation workflows.
Required Skills & Qualifications
* 2–3 years experience in IoT, embedded systems, or industrial automation.* Strong knowledge of PLCs and industrial protocols (Modbus, OPC-UA, Profinet).* Hands-on experience with sensors and instrumentation.* Experience with microcontrollers (ESP32, STM32) and embedded systems.* Experience with MQTT, REST APIs, and edge computing.* Understanding of networking fundamentals (Wi-Fi, Ethernet).* Ability to read electrical schematics and troubleshoot industrial systems.* Strong analytical and problem-solving skills.* Bachelor’s degree in Electronics, Electrical, Mechatronics, or related field.
Preferred (Nice to Have)
* Experience in printing/packaging machinery (Heidelberg, Prinect, CIP4/JDF).* Experience in OEE or machine monitoring systems.* Knowledge of RS485/Modbus and power monitoring systems.* Experience deploying large numbers of IoT devices in industrial environments.* Familiarity with Node-RED or Python-based IoT workflows.* Exposure to AI-based CCTV or video analytics systems.* Experience with ruggedized industrial hardware design.