Every major manufacturer in America is automating. The question isn't whether; it's how fast. And the bottleneck isn't robots or PLCs. It's the people who can install, program, troubleshoot, and maintain them.
Automation technicians, also called controls technicians, PLC technicians, or mechatronics technicians, are the bridge between the machines and the production floor. The Bureau of Labor Statistics projects 16% growth for electro-mechanical and mechatronics technicians through 2033, nearly three times the national average. Industry sources estimate over 40,000 unfilled automation technician positions across U.S. manufacturing at any given time.
This guide covers what automation technicians actually do, what they earn, the specific technical skills you need, how to get trained, and where the career is headed with Industry 4.0.
What Automation Technicians Do
Your day-to-day depends on whether you work in integration (building new systems), production support (keeping systems running), or a combination. Here's how the work breaks down:
PLC Programming & Troubleshooting
- Write, modify, and debug PLC (Programmable Logic Controller) programs
- Troubleshoot I/O failures, communication faults, and logic errors
- Modify ladder logic, function blocks, and structured text for production changes
- Primary platforms: Allen-Bradley (ControlLogix/CompactLogix, Studio 5000), Siemens (S7-1500, TIA Portal), Omron, Mitsubishi
Robotics
- Program, teach, and maintain industrial robots for welding, material handling, palletizing, and assembly
- Perform TCP (Tool Center Point) calibration, path optimization, and collision zone setup
- Primary platforms: FANUC (most common in North America), ABB, KUKA, Yaskawa/Motoman, Universal Robots (cobots)
HMI & SCADA
- Design and modify HMI (Human Machine Interface) screens that operators use to monitor and control production
- Configure SCADA systems for data collection, alarming, and production tracking
- Tools: FactoryTalk View, Ignition, WonderWare, Siemens WinCC
Drives & Motor Controls
- Install, configure, and troubleshoot VFDs (Variable Frequency Drives) and servo drives
- Set up motor parameters, speed references, and fault recovery logic
- Common brands: Allen-Bradley PowerFlex, Siemens SINAMICS, ABB ACS, Yaskawa
Sensors & Instrumentation
- Install and calibrate proximity sensors, photoelectric sensors, encoders, pressure transducers, and flow meters
- Troubleshoot sensor failures and wiring issues on production equipment
- Configure analog signals (4-20mA, 0-10V) and digital I/O
Networking & Communication
- Configure industrial Ethernet (EtherNet/IP, PROFINET), DeviceNet, serial communication
- Troubleshoot network faults between PLCs, HMIs, robots, and enterprise systems
- Increasingly: integrate IoT devices and edge computing platforms
Automation Technician Salary Data (2026)
Automation technicians earn significantly more than general maintenance techs because of the specialized programming and troubleshooting skills required.
| Experience Level | Median Salary | Range | Typical Title | |-----------------|--------------|-------|---------------| | Entry (0-2 years) | $52,000 | $42,000-$60,000 | Controls Technician I | | Mid (3-5 years) | $68,000 | $58,000-$78,000 | Automation Technician | | Senior (6-10 years) | $82,000 | $72,000-$95,000 | Senior Controls Tech | | Lead/Specialist (10+ years) | $95,000 | $85,000-$115,000 | Controls Engineer/Specialist |
Highest-Paying Industries for Automation Technicians
| Industry | Median Salary | Why It Pays More | |----------|--------------|-----------------| | Semiconductor Manufacturing | $88,000 | Extreme precision, cleanroom environments | | Pharmaceutical / Biotech | $84,000 | FDA validation requirements, GMP compliance | | Automotive (OEM Assembly) | $78,000 | UAW contracts, high-volume production complexity | | Food & Beverage | $72,000 | Sanitary design, 24/7 operations | | General Manufacturing | $66,000 | Broadest category, highest job volume | | System Integrators | $74,000 | Travel premium, project-based work |
Highest-Paying States
| State | Mean Annual Wage | Key Employers | |-------|-----------------|---------------| | Michigan | $78,400 | Automotive OEMs and Tier 1 suppliers | | California | $76,800 | Semiconductor, aerospace, food processing | | Texas | $74,200 | Oil & gas, semiconductor (Samsung, TI), food | | Ohio | $72,600 | Automotive, aerospace (GE), consumer goods (P&G) | | Indiana | $70,800 | Automotive, pharmaceutical (Eli Lilly), logistics | | Arizona | $73,500 | Semiconductor (Intel, TSMC), aerospace (Raytheon) |
Overtime is common, especially during equipment installations, plant shutdowns for upgrades, and production ramp-ups. Many automation techs earn 10-25% above base salary through overtime and on-call premiums.
Required Skills: The Technical Stack
Here's what employers actually screen for, ranked by how frequently they appear in job postings on HireBuilt:
Tier 1: Must-Have (Appears in 80%+ of postings)
- PLC programming (Allen-Bradley Studio 5000 / RSLogix 5000 is the most requested platform in North America)
- Electrical troubleshooting (480V 3-phase, motor controls, reading schematics)
- Industrial networking (EtherNet/IP, basic IT networking concepts)
- VFD configuration (Allen-Bradley PowerFlex or equivalent)
- Sensor installation and calibration
Tier 2: Strongly Preferred (Appears in 50-80% of postings)
- HMI development (FactoryTalk View, Ignition)
- Robot programming (FANUC TP or RAPID for ABB)
- Servo drive setup (Kinetix for Allen-Bradley, SINAMICS for Siemens)
- Vision systems (Cognex, Keyence)
- Pneumatic and hydraulic systems
Tier 3: Differentiators (Appears in 20-50% of postings)
- Siemens TIA Portal (growing demand, especially at European-owned plants)
- SCADA/data historian (Ignition, OSIsoft PI, Wonderware)
- Python or SQL (for data analysis and integration)
- Safety systems (GuardLogix, Pilz, SICK safety controllers)
- CAD/electrical design (AutoCAD Electrical, EPLAN)
If you're coming from an industrial maintenance background, you likely already have Tier 1 electrical skills. Adding PLC programming and robotics is the fastest path to automation-level pay.
Certifications
Siemens Certified Mechatronics Systems Associate (SMSCP Level 1-2)
Siemens offers a tiered certification program validated through Pearson VUE testing centers. Level 1 covers mechatronics fundamentals; Level 2 covers advanced automation including PLC, HMI, and networking. Strong recognition at plants running Siemens equipment.
Rockwell Automation Certifications
Rockwell (Allen-Bradley) doesn't offer traditional certifications, but their training courses through Rockwell Automation University are widely recognized. Completing courses in Studio 5000, FactoryTalk View, and PowerFlex drives signals competence to any employer running Allen-Bradley equipment.
FANUC Certified Robot Operator / Technician
FANUC offers certifications through their Authorized Satellite Training (FAST) centers. Handling, programming, and maintenance certifications validate your ability to work with the most widely deployed robot brand in North America.
PMMI Mechatronics Certification
The Packaging Machinery Manufacturers Institute offers certifications focused on packaging line automation, a huge niche in food, beverage, and consumer goods manufacturing.
ISA Certified Automation Professional (CAP)
The International Society of Automation's CAP credential covers automation system design, implementation, and management. More suited for senior technicians or those transitioning toward controls engineering.
For a broader view of which credentials move the needle, see our post on safety certifications every tradesperson needs.
Training Paths
1. Mechatronics / Automation Technology Degree (1-2 years)
The most direct path. Community college and technical college programs in mechatronics or automation technology cover:
- Electrical fundamentals and motor controls
- PLC programming (usually Allen-Bradley and/or Siemens)
- Industrial robotics (often FANUC)
- Hydraulics and pneumatics
- Industrial networking
- Sensors and instrumentation
Cost: $4,000-$20,000 depending on institution Best programs: Schools with Siemens SMSCP or FANUC CERT partnerships
2. From Industrial Maintenance (Lateral Move)
Many automation technicians start as industrial maintenance techs and upskill into controls. If you already have electrical and mechanical troubleshooting skills, adding PLC programming through vendor courses or a short certificate program is often enough to make the jump. Expect a $10,000-$20,000 salary increase when you transition from general maintenance to automation.
3. Military Technical Training
Veterans with MOS codes in electronics, avionics, or fire control systems have directly transferable skills. The systematic troubleshooting methodology taught in military technical training translates perfectly to industrial automation. For details on leveraging military experience, see our veterans guide to skilled trades careers.
4. Apprenticeship
Some manufacturers, particularly automotive OEMs and large food companies, run formal automation/controls apprenticeships. These combine classroom PLC and robotics training with paid on-the-job experience. Check our complete guide to trade apprenticeships for how to find them.
Career Progression
Automation has one of the steepest earning curves in the skilled trades because each skill layer you add increases your value significantly.
Controls Technician I (Year 0-2): $42,000-$60,000 Basic PLC troubleshooting, sensor replacement, VFD parameter changes. Working under supervision of senior techs.
Automation Technician (Year 3-5): $58,000-$78,000 Independent PLC programming, robot teaching, HMI modifications. Handling most issues without escalation.
Senior Controls Technician (Year 6-10): $72,000-$95,000 System design input, complex troubleshooting, mentoring junior techs. Leading equipment commissioning and upgrades.
Controls Specialist / Engineer (Year 10+): $85,000-$115,000 Some companies create non-degreed "controls engineer" roles for experienced automation techs. You'll design systems, manage integration projects, and serve as the plant's automation subject matter expert.
System Integrator (Alternative path): $70,000-$110,000+ with travel System integrators build and program automated systems for manufacturers. The work involves travel (often 50-75%) but pays well and exposes you to diverse industries and technologies. Many automation techs go this route for a few years to accelerate skill development.
Industry 4.0 and What's Next
The automation technician role is evolving. Here's what's changing and what it means for your career:
IIoT and Edge Computing. Manufacturers are connecting equipment to cloud platforms for predictive maintenance, production analytics, and remote monitoring. Technicians who understand MQTT, OPC-UA, and basic networking will be increasingly valuable.
Collaborative Robots (Cobots). Universal Robots, FANUC CRX, and ABB GoFa are appearing on production floors that never had traditional robots. Cobots are simpler to program but still need technicians to deploy, maintain, and optimize them.
Vision and AI Inspection. Automated visual inspection using machine learning is replacing manual quality checks. Cognex and Keyence vision systems are already table stakes; AI-driven inspection platforms are next.
Convergence of IT and OT. The line between information technology and operational technology is blurring. Automation techs who can speak both languages (configure a PLC and troubleshoot an Ethernet switch) will be the most employable technicians in manufacturing.
The bottom line: automation technicians who keep learning will never lack for work. The BLS data and industry trends all point the same direction: more automation, more demand, higher pay.
For a comparison against other high-paying trades, see the top 10 highest-paying trade jobs in 2026.
Browse Automation Technician Jobs on HireBuiltReal automation and controls technician openings from manufacturers and integrators. Search by location and specialization.
Salary data sourced from Bureau of Labor Statistics (May 2025 OES), employer postings on HireBuilt, and industry salary surveys from ISA and PMMI. Job growth projections from BLS Occupational Outlook Handbook (Electro-Mechanical and Mechatronics Technologists and Technicians, SOC 17-3024). Actual salaries vary by location, industry, experience, and employer.
