Senior Automation Specialist, Fabrication and Weld

Blue Bird (NASDAQ: BLBD) is recognized as a technology leader and innovator of school buses since its founding in 1927. Our dedicated team members design, engineer and manufacture school buses with a singular focus on safety, reliability, and durability. School buses carry the most precious cargo in the world – 25 million children twice a day – making them the most trusted mode of student transportation. The company is the proven leader in low- and zero-emission school buses with more than 25,000 propane, natural gas, and electric powered buses sold. Blue Bird is transforming the student transportation industry through cleaner energy solutions. For more information on Blue Bird’s complete product and service portfolio, visit www.blue-bird.com.

The Senior Automation Specialist, Fabrication and Weld delivers and sustains automated manufacturing equipment and process capability across the equipment lifecycle. This role focuses on equipment performance, process robustness, and reliability to meet safety, quality, throughput, and cost objectives. The specialist leads equipment acceptance activities (FAT/SAT/Run-at-Rate), validates capability targets (e.g., Cp/Cpk, OEE, MTBF/MTTR), and partners with Operations, Maintenance, Quality, Manufacturing Engineering, and suppliers/integrators to implement scalable, maintainable automation solutions.

• Design, specify, program, and commission automated manufacturing equipment, including:
• PLC‑controlled systems
• Robotics and motion systems
• Vision inspection systems
• Material handling and part tracking solutions

• Develop, test, and maintain PLC control logic for automated manufacturing equipment (discrete, continuous, and motion applications).
• Build and sustain HMI interfaces for machine control, diagnostics, alarms, and operator interaction.
• Define and validate equipment capability (Cp/Cpk, OEE, MTBF, MTTR) to ensure systems meet production and quality requirements.
• Lead equipment buy‑off activities, including FAT, SAT, and Run‑at‑Rate support.

• Develop and refine robot programs (online/offline) to support applications such as material handling, assembly, welding, dispensing, and palletizing.
• Optimize robot motion and interactions for cycle time, repeatability, reliability, and safe recovery.
• Integrate robots and vision systems with PLCs, safety circuits, and peripheral equipment, support commissioning and validation activities.

• Translate product and process requirements into automation solutions that are repeatable, stable, scalable, and maintainable.
• Develop and validate process windows and settings within automated equipment to ensure consistent output across shifts and lots.
• Identify automation-driven risks and implement mitigation (poka-yoke, interlocks, detection/verification, alarms) to protect quality and safety.
• Support continuous improvement initiatives targeting yield, cycle time, scrap reduction, and labor efficiency.

• Support start‑up, ramp, and high‑volume production through hands‑on troubleshooting and optimization.
• Partner with Maintenance to develop:
• Preventive maintenance strategies
• Spare parts lists
• Technical documentation and training materials
• Drive corrective actions for chronic equipment or process issues.
• Support modifications and retrofits driven by process changes, cost reduction, or obsolescence.

• Collaborate with Product Engineering, Manufacturing Engineering, Quality, Operations, and Maintenance throughout equipment development and deployment.
• Manage automation suppliers and integrators for technical scope definition, deliverables, timelines, and performance accountability (as assigned).
• Support PFMEA/DFMEA contributions, control plan development, and quality audits related to automated processes.

• Strong knowledge of welding processes and equipment (GMAW, SMAW, GTAW)
• Experience in weld training and/or inspection
• Working knowledge of automated equipment capability and manufacturing process control, including Cp/Cpk, OEE, MTBF, and MTTR.
• Experience supporting or commissioning industrial robots (e.g., FANUC, ABB, KUKA, Yaskawa) and integrating with equipment/process requirements.
• Proficiency troubleshooting control systems and complex electromechanical systems in a production environment.
• Experience integrating or supporting vision systems (e.g., Cognex, Keyence) and automated detection/verification strategies.
• Working knowledge of functional safety concepts and applicable standards (ANSI/ISO/OSHA and internal safety requirements).
• Familiarity with Lean Manufacturing and Six Sigma principles; ability to apply structured problem-solving methods.
• Strong systems-level thinking with focus on equipment-process interaction and sustainable countermeasures.
• Clear technical communication with operators, engineers, maintenance teams, and suppliers/integrators; results-oriented mindset.

• High School Diploma or GED required
• 5+ years of experience in fabrication and welding
  • Industrial automation and programming within a manufacturing environment, preferred
• AWS-CWI required or have the ability to obtain within 90 days of hire.
• All candidates must be a U.S. citizen or permanent resident

• Ability to anticipate and understand customer needs and provide guidance
• Excellent interpersonal and customer relationship skills to handle difficult and sensitive matters.
• Strong project management skills. Exposure to difficult or complex projects a plus.
• Ability to influence stakeholders
• Effective communication and ability to communicate complex details in a clear manner.
• Flexible workspaces and work hours that help you unleash the best you.
• Working in a collaborative team and balancing the needs of individual stakeholders while delivering corporate objectives.

• Continued Professional Development
• Benefits including medical, dental and vision insurance, 14 paid holidays, vacation time and 401k matching

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Manufacturing environment with exposure to heat, cold and noise
• Must be able to work as necessary
• Must be able to work with diverse workforce
• Weekends and travel as required

PERFORMANCE CRITERIA:

• Able to meet engineering standards and procedures
• Follow company policy and procedures
• Successful project completion
• Must meet established department goals
• Must work within budgetary boundaries

*The specific statements shown in each section of this description are not intended to be all-inclusive.  They represent typical elements and criteria necessary to successfully perform the job.  Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions

Blue Bird® is an equal opportunity employer and makes employment decisions on the basis of merit. We strive to have the best available talent in every job based on the Knowledge, Skills and Abilities each person brings.  Blue Bird is committed to compliance with all applicable laws providing equal employment opportunities. This commitment applies to all persons involved in Company operations and prohibits unlawful discrimination in all forms.

All candidates must be a U.S. citizen or permanent resident. Candidates must be authorized to work in the United States and will be required to provide proof of employment eligibility at the time of hire

LI-Onsite