Automation & Maintenance Technician

Job Description

Job Description:\n\n KULR Technology Group is a publicly traded company (NYSE: KULR) with a vibrant startup dynamic, headquartered in Houston, TX Our mission is developing energy management platforms to accelerate the global transition to a circular electrification economy. We create sustainable solutions that benefit humanity using space proven engineering, making the world of batteries and electronics cooler, lighter, and safer. We operate in four verticals: e-mobility, environmental/energy storage, industrial/consumer tools, and aerospace/defense. Our technologies have been deployed by NASA, including applications on the Space Station and Mars Rover. Job Title: Automation & Maintenance Technician FLSA Status: Non-Exempt Salary: $35 - $41/hour Reports to: Director of Operations Location: Onsite KULR Technology Location: Webster, Texas Travel: Some travel required for customer meetings, conferences, and design reviews. Position Overview: The Automation & Maintenance Technician is a critical dual-role position on KULR's manufacturing team, responsible for two equally important functions: (1) the programming, commissioning, troubleshooting, and maintenance of PLC and automation systems across battery pack production and test operations, and (2) the setup, commissioning, and ongoing preventive maintenance of all production equipment at the Webster facility. This role requires a hands-on technical expert who can bridge automation controls, mechanical systems, and equipment reliability — ensuring maximum uptime, precision, and throughput across all of KULR's production lines. This is a foundational role in a fast-scaling, greenfield manufacturing environment. The ideal candidate takes full ownership of every system they touch — from writing ladder logic to building the PM schedule from the ground up. They move fast, document thoroughly, and treat every piece of equipment as their personal responsibility. They understand that in a manufacturing environment, uptime is revenue. Functions: PLC Programming & Automation Program, configure, and maintain PLCs across multiple platforms (Allen-Bradley / Rockwell, Siemens, Mitsubishi, or equivalent) for battery pack assembly, testing, and automated inspection systemsDevelop and modify ladder logic, function block diagrams, structured text, and HMI screens to support production requirements and continuous process improvementsDesign and implement automated control sequences for assembly line equipment, test stations, and material handling systemsIntegrate PLC systems with SCADA, MES, and data acquisition platforms to support real-time monitoring and KPI trackingMaintain version control and full documentation of all PLC programs, including change logs, revision history, and network diagrams Equipment Setup & Commissioning Receive, install, and commission all new production equipment at the Webster facility — coordinate with vendors and OEMs through FAT (Factory Acceptance Testing) and SAT (Site Acceptance Testing)Develop and maintain equipment setup documentation and SOPs for all production machines — ensuring operators have clear, accurate startup and shutdown proceduresConfigure and calibrate equipment to production specifications prior to handoff to the production team — validate output quality before releasing to productionMaintain a comprehensive equipment inventory list with specifications, serial numbers, OEM service contacts, and warranty information for all production machineryCollaborate with engineering on design-for-maintainability reviews for new equipment — flag serviceability concerns before equipment is purchased or committed Preventive Maintenance Program Own and manage the full PM program for all production equipment — build the program from scratch, implement it, and continuously improve it based on equipment history and failure dataDevelop PM schedules and checklists for each piece of equipment based on OEM recommendations, production run rates, and operational experienceExecute all scheduled PMs and document completion in NetSuite — no deferred maintenance without documented escalation and approvalTrack and report equipment downtime, MTBF (Mean Time Between Failures), and MTTR (Mean Time to Repair) — present monthly summary to operations leadershipManage the spare parts inventory for critical equipment components — establish min/max levels in NetSuite and ensure key spares are always on handCoordinate with vendors and OEMs for specialized or annual PM services that require third-party involvement — manage scheduling and documentation of those visitsEnsure all equipment is calibrated and within tolerance per applicable quality standards — maintain calibration records and certificates for audit readiness Troubleshooting & Corrective Maintenance Diagnose and resolve faults across all production equipment — electrical, PLC/software, mechanical, pneumatic, and hydraulic — minimizing downtime and protecting throughputPerform minor mechanical repairs including bearings, belts, chain drives, pneumatic actuators, and associated mechanical systemsRespond to production line breakdowns with urgency — implement root cause corrective actions and document all findings, causes, and resolutions in NetSuiteConduct regular system audits to identify aging components, obsolescence risks, and upgrade opportunities before they cause production failures Process Improvement & Engineering Support Collaborate with manufacturing engineers and production leadership to identify automation opportunities that reduce cycle time, improve yield, and eliminate manual bottlenecksSupport introduction of new production lines — from specification review through commissioning and operator handoffParticipate in PFMEA, risk assessments, and equipment design reviews for new automation and production equipmentContribute to continuous improvement initiatives including OEE improvement, cycle time reduction, and error-proofing (poka-yoke) Safety & Compliance Champion electrical, mechanical, and machine safety — ensure all equipment meets OSHA, NFPA, and applicable IEC/ANSI safety standardsPerform LOTO (Lockout/Tagout) procedures and enforce safe work practices during all maintenance and installation activities — no exceptionsEnsure all equipment has current calibration records, PM logs, and machine guarding compliant with OSHA and NFPA 79 — maintain audit-ready documentation at all timesParticipate in safety committee reviews, hazard assessments, and incident investigations related to automation and production equipmentMaintain compliance with all environmental, health, and safety requirements applicable to lithium-ion battery manufacturing operations Documentation & Reporting Maintain complete, up-to-date documentation for all PLC systems and production equipment — program backups, I/O lists, PM records, calibration certificates, spare parts lists, and equipment manualsGenerate maintenance reports, downtime logs, PM completion records, and corrective action documentation in NetSuiteTrain production and maintenance staff on basic equipment operation, HMI navigation, PM participation, and first-response troubleshooting proceduresOther job-related duties as assigned. Supervisory Responsibilities: N/A. REQUIREMENTS Education & Experience: Associate degree or technical certificate in Electrical Technology, Industrial Automation, Mechatronics, or related field — or equivalent hands-on experienceMinimum 3–5 years of hands-on experience in industrial automation, equipment maintenance, or a combined controls and maintenance role in a manufacturing environmentProficiency in at least one major PLC platform: Allen-Bradley (Studio 5000 / RSLogix), Siemens (TIA Portal / Step 7), or Mitsubishi (GX Works)Demonstrated experience building or managing a preventive maintenance program in a manufacturing environment — not just executing PMs written by othersWorking knowledge of mechanical systems — pneumatics, hydraulics, drives, bearings, belts, conveyors, and general industrial machineryExperience with HMI development (FactoryTalk View, Ignition, Wonderware, or similar)Ability to read and interpret electrical schematics, wiring diagrams, P&IDs, OEM manuals, and mechanical drawingsSolid working knowledge of industrial electrical systems: 120V, 240V, 480V AC; 24VDC control circuitsFamiliarity with industrial communication protocols: EtherNet/IP, Modbus, Profibus, DeviceNetExperience with CMMS or ERP-based maintenance tracking — NetSuite or equivalentLOTO certified with a demonstrated commitment to electrical and mechanical safety best practices Preferred: Bachelor's degree in Electrical Engineering, Mechanical Engineering, Controls Engineering, or related fieldExperience in a new facility standup or greenfield manufacturing environment — setting up equipment, building PM programs, and establishing operational standards from scratchExperience in battery manufacturing, electronics assembly, or regulated manufacturing (ISO 9001, IATF 16949, or AS9100)Familiarity with TPM (Total Productive Maintenance) methodology and OEE improvement frameworksExperience with predictive maintenance techniques — vibration analysis, thermal imaging (IR), or oil analysisFamiliarity with SCADA systems and MES integration and real-time data acquisition for equipment monitoringExperience with robot integration (FANUC, KUKA, Universal Robots, or similar)Knowledge of machine safety standards: ISO 13849, IEC 62061, NFPA 79Rockwell Automation Certified Specialist (Studio 5000) or equivalent certificationExperience with vision systems (Cognex, Keyence, or similar) and barcode/RFID integrationSix Sigma Green Belt or Lean Manufacturing certification Knowledge, Skills and Abilities (KSAs): Advanced knowledge of PLC programming across multiple platforms (e.g., Allen-Bradley/Rockwell, Siemens, Mitsubishi), including ladder logic, structured text, and HMI development for automated manufacturing systems Ability to design, implement, and optimize automated control systems for production equipment, test stations, and material handling processes Proficiency in integrating PLCs with SCADA, MES, and data acquisition systems to enable real-time monitoring and performance tracking Strong understanding of equipment commissioning processes, including FAT/SAT coordination, system validation, and production readiness verification Demonstrated capability in developing and managing preventive maintenance programs, including PM schedules, checklists, and continuous improvement based on failure data Expertise in troubleshooting complex systems across electrical, mechanical, pneumatic, hydraulic, and controls domains with a focus on minimizing downtime Working knowledge of reliability metrics (MTBF, MTTR, downtime analysis) and ability to use data to drive maintenance and operational improvements Experience managing spare parts inventory, equipment documentation, calibration records, and maintenance tracking systems (e.g., NetSuite or equivalent CMMS) Ability to collaborate cross-functionally with engineering and operations teams on process improvements, new equipment introduction, and design-for-maintainability initiatives Strong knowledge of safety and compliance standards (OSHA, NFPA, LOTO) with a consistent track record of maintaining audit-ready documentation and safe work practices Physical Demands/Work Environment: The work environment characteristics described here represent those an employee may encounter while performing this job's essential functions. Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions. Office Work Environment Sedentary work. Exerting up to 25 pounds of force occasionally and/or negligible amount of force frequently or constantly to lift, carry, push, pull or otherwise move objects. Close visual acuity to perform an activity such as preparing and analyzing data and viewing a computer terminal. Sufficient clarity of speech and hearing or other communication capabilities, which permits the employee to communicate effectively on the telephone and in person. Sufficient manual dexterity with or without reasonable accommodation, which permits the employee to frequently operate a personal computer (estimated 50%-75% of the typical workday) and other office equipment. Sufficient personal mobility and physical reflexes, with or without reasonable accommodation, which permit the employee at a computer workstation for an extended period. Test Facility Work Environment Standing for long periods of time, climbing up and down ladders, bending, grasping, sitting, pulling, pushing, stooping, and stretching are generally required to perform the functions of this position.Must be able to lift up to 50 lbs. unassisted.Noisy environments. OccasionallyHazardous conditions. OccasionallySmall and/or enclosed spaces. OccasionallyOperating machinery and/or power tools. ConstantlyRepeating motions that may include the wrists, hands and/or fingers. OccasionallyAdjusting or moving objects up to 50 pounds in all directions. OccasionallyRemaining in a stationary position, often standing or sitting for prolonged periods. ConstantlyMoving about to accomplish tasks or moving from one worksite to another. OccasionallySedentary work that primarily involves sitting/standing. OccasionallyMoving self in different positions to accomplish tasks in various environments including tight and confined spaces. OccasionallyLight work that includes moving objects up to 20 pounds. Occasionally Medium work that includes moving objects up to 50 pounds. Occasionally Heavy work that includes moving objects up to 100 pounds or more. OccasionallyAscending or descending ladders, stairs, scaffolding, ramps, poles and the like. Occasionally Special Conditions: Employment is contingent upon successful completion of a criminal background check.Must have a current, valid driver’s license.Must be able to provide own transportation between work locations. Must be able to work various hours and locations based on business needs.Must be a U.S. Citizen due to federal contract requirements. Successful applicant must meet ITAR requirements.Must be able to work beyond 40h and weekends as needed. Must able to work during KULR core hours of 8:30am to 4:00pm (remaining daily time is flexible) DISCLOSURE AND ACKNOWLEDGEMENT: All job requirements are subject to possible modification to reasonably accommodate individuals with disabilities. Some requirements may exclude individuals who pose a direct threat or significant risk to the health and safety of themselves or others. This job description in no way states or implies that these are the only duties to be performed by the incumbent of this position. Employees will be required to follow any other job-related instructions and to perform other job-related duties requested by the supervisor in compliance with federal and state Laws. Requirements are representative of minimum levels of knowledge, skills and/or