Automation Engineer Interview: Questions, Tasks, and Tips

Get ready for a Automation Engineer interview. Discover common HR questions, technical tasks, and best practices to secure your dream IT job. Automation Engineer represents an exciting career path in the technology sector. The role requires both technical proficiency and creative thinking, providing clear advancement opportunities.

Share
Popular Prep Guides

Backend Developer SMM Data Scientist Virtual Assistant DevOps Engineer Content Writer

Role Overview

Comprehensive guide to Automation Engineer interview process, including technical evaluations, system design assessments, and process optimization scenarios.

Categories

Industrial Automation Control Systems Robotics Process Optimization

Seniority Levels

Junior Middle Senior Lead

Interview Process

Average Duration: 4-5 weeks

Overall Success Rate: 50%

Success Rate by Stage

Technical Screening 70%
System Design Challenge 55%
On-site Technical Interview 60%
Safety and Compliance Review 65%
Cross-Functional Collaboration 75%

Success Rate by Experience Level

Junior 30%
Middle 50%
Senior 70%

Interview Stages

Technical Screening

Duration: 60 minutes Format: Coding test
Focus Areas:

PLC programming and control systems

Participants:
  • Technical Recruiter
Success Criteria:
  • Programming proficiency
  • System architecture understanding
  • Problem-solving approach
  • Technical knowledge depth
Preparation Tips:
  • Review PLC ladder logic
  • Study industrial protocols
  • Practice control system design

System Design Challenge

Duration: 4 hours Format: Take-home assignment
Focus Areas:

Complete automation solution design

Required Materials:
  • CAD software
  • PLC programming tools
  • Simulation environment
Evaluation Criteria:
  • System architecture
  • Component selection
  • Safety considerations
  • Implementation feasibility

On-site Technical Interview

Duration: 90 minutes Format: Whiteboard session
Focus Areas:

Process optimization and troubleshooting

Participants:
  • Automation Manager
  • Senior Engineer

Safety and Compliance Review

Duration: 60 minutes Format: Panel interview
Focus Areas:

Industrial safety standards

Participants:
  • Safety Officer
  • Quality Manager
Typical Discussion Points:
  • Risk assessment methodologies
  • Safety system design
  • Regulatory compliance
  • Incident prevention strategies

Cross-Functional Collaboration

Duration: 75 minutes Format: Role-play exercise
Focus Areas:

Stakeholder alignment and project management

Evaluation Criteria:
  • Technical translation ability
  • Stakeholder management
  • Conflict resolution
  • Strategic thinking

Interview Questions

Common HR Questions

Q: Describe your approach to automation system design
What Interviewer Wants:

Structured design methodology

Key Points to Cover:
  • Requirement analysis
  • Component selection
  • Control strategy
  • Implementation planning
Good Answer Example:

I follow systematic design process: 1) Detailed process analysis, 2) Select appropriate control architecture (DCS/PLC/SCADA), 3) Design safety systems per SIL ratings, 4) Implement energy-efficient solutions, 5) Develop comprehensive documentation. Recent project achieved 30% energy savings through optimized control strategy.

Bad Answer Example:

I design systems based on client requirements.

Q: How do you ensure system reliability?
What Interviewer Wants:

Robustness and maintenance strategies

Key Points to Cover:
  • Redundancy design
  • Predictive maintenance
  • Failure mode analysis
  • Monitoring systems
Good Answer Example:

Implement multi-layer reliability: 1) Hardware redundancy for critical components, 2) Predictive maintenance using IIoT sensors, 3) FMEA for all subsystems, 4) Real-time monitoring with anomaly detection. Reduced downtime by 40% in current plant.

Bad Answer Example:

I use high-quality components and regular maintenance.

Q: Explain your experience with industrial protocols
What Interviewer Wants:

Technical proficiency and implementation knowledge

Key Points to Cover:
  • Protocol selection criteria
  • Integration challenges
  • Performance optimization
  • Security considerations
Good Answer Example:

Extensive experience with PROFINET, Modbus, and OPC UA: Implemented plant-wide communication network integrating 500+ devices across 15 protocols. Developed protocol conversion gateway improving data throughput by 50%. Implemented cybersecurity measures meeting IEC 62443 standards.

Bad Answer Example:

I've worked with common industrial protocols.

Q: Describe a challenging automation project
What Interviewer Wants:

Problem-solving and technical depth

Key Points to Cover:
  • Project complexity
  • Technical challenges
  • Solution approach
  • Measured outcomes
Good Answer Example:

Automated pharmaceutical packaging line: Integrated vision systems with robotic arms, implemented real-time quality control, achieved 99.9% accuracy. Developed custom PLC program handling 200+ product variants. Reduced changeover time by 70% through smart recipe management.

Bad Answer Example:

I worked on several automation projects.

Behavioral Questions

Q: Tell me about a time you improved production efficiency
Situation:

Underperforming production line

Task:

Increase throughput without compromising quality

Action:

Automation system optimization

Result:

Significant efficiency gains

Good Answer Example:

For automotive assembly line running at 65% efficiency: Analyzed bottleneck operations, implemented robotic welding cells with vision guidance, optimized PLC cycle times. Increased throughput by 35% while improving weld quality consistency.

Metrics to Mention:
  • Throughput improvement
  • Quality metrics
  • Energy savings
  • ROI
Q: Describe handling equipment failure under production pressure
Situation:

Critical system failure

Task:

Minimize downtime

Action:

Rapid troubleshooting and solution implementation

Result:

Production resumed with minimal impact

Good Answer Example:

During PLC failure in 24/7 operation: Quickly diagnosed faulty I/O module, implemented temporary manual override while coordinating replacement, updated maintenance procedures to prevent recurrence. Limited downtime to 2 hours vs potential 8-hour outage.

Motivation Questions

Q: Why specialize in industrial automation?
What Interviewer Wants:

Career alignment and technical passion

Key Points to Cover:
  • Interest in manufacturing technology
  • Technical challenge appeal
  • Impact potential
  • Future vision
Good Answer Example:

I'm fascinated by the intersection of mechanical, electrical, and software systems in modern manufacturing. Automation engineering allows me to solve complex technical challenges while driving tangible business impact. The field's rapid evolution and Industry 4.0 transformation provide constant intellectual stimulation.

Bad Answer Example:

I enjoy working with machines and technology.

Technical Questions

Basic Technical Questions

Q: Explain PID controller tuning

Expected Knowledge:

  • Control theory fundamentals
  • Tuning methods
  • Stability analysis
  • Practical implementation

Good Answer Example:

I use systematic tuning approach: 1) Start with Ziegler-Nichols method for initial values, 2) Fine-tune using lambda method for better response, 3) Implement anti-windup protection, 4) Validate with step response testing. Recently optimized temperature control achieving ±0.1°C stability.

Tools to Mention:

MATLAB Siemens TIA Portal Rockwell Studio 5000
Q: Key considerations for robotic cell design

Expected Knowledge:

  • Safety standards
  • Cycle time optimization
  • End effector selection
  • Integration requirements

Good Answer Example:

Comprehensive design approach: 1) Risk assessment per ISO 10218, 2) Cycle time analysis with simulation, 3) Proper end effector selection for task requirements, 4) Integration with existing systems. Designed 10+ cells achieving 99.5% uptime.

Tools to Mention:

RobotStudio RoboDK Visual Components

Advanced Technical Questions

Q: Design IIoT implementation strategy

Expected Knowledge:

  • Sensor network design
  • Data analytics
  • Cloud integration
  • Cybersecurity

Good Answer Example:

Strategic IIoT implementation: 1) Deploy edge devices for local processing, 2) Implement OPC UA for secure communication, 3) Use time-series database for efficient data storage, 4) Develop predictive maintenance models. Reduced maintenance costs by 25% in pilot implementation.

Tools to Mention:

Node-RED InfluxDB Grafana
Q: Implement machine learning in process control

Expected Knowledge:

  • Data collection
  • Model training
  • System integration
  • Performance monitoring

Good Answer Example:

Implemented ML-based quality prediction: 1) Collected sensor data with proper time-stamping, 2) Trained LSTM model for defect prediction, 3) Integrated with PLC for real-time control, 4) Continuous model retraining. Achieved 95% prediction accuracy reducing scrap by 20%.

Tools to Mention:

TensorFlow PyTorch SCADA integration

Practical Tasks

Control System Design

Develop complete automation solution

Duration: 1 week

Requirements:

  • System architecture
  • Component selection
  • Safety considerations
  • Implementation plan

Evaluation Criteria:

  • Technical feasibility
  • Innovation
  • Cost-effectiveness
  • Maintainability

Process Optimization Challenge

Improve existing production process

Duration: 3 days

Requirements:

  • Process analysis
  • Optimization strategy
  • Implementation plan
  • ROI calculation

Common Mistakes:

  • Ignoring safety
  • Overlooking maintenance
  • Incomplete testing
  • Poor documentation

Troubleshooting Simulation

Diagnose and resolve system failure

Duration: 4 hours

Deliverables:

  • Root cause analysis
  • Corrective action plan
  • Prevention strategy
  • Documentation

Evaluation Criteria:

  • Diagnostic accuracy
  • Solution effectiveness
  • Response time
  • Communication clarity

Industry Specifics

Manufacturing

Focus Areas:

  • Production line automation
  • Quality control systems
  • Material handling
  • Process optimization

Energy

Focus Areas:

  • SCADA systems
  • Predictive maintenance
  • Grid optimization
  • Renewable energy integration

Pharmaceuticals

Focus Areas:

  • Clean room automation
  • Batch process control
  • Regulatory compliance
  • Data integrity

Skills Verification

Must Verify Skills:

PLC Programming

Verification Method: Coding test

Minimum Requirement: 3+ years professional experience

Evaluation Criteria:
  • Code quality
  • Problem-solving
  • Efficiency
  • Documentation
System Integration

Verification Method: Design exercise

Minimum Requirement: Completed automation projects

Evaluation Criteria:
  • Architecture design
  • Component selection
  • Implementation planning
  • Risk management
Process Optimization

Verification Method: Case study analysis

Minimum Requirement: Proven efficiency improvements

Evaluation Criteria:
  • Analytical approach
  • Innovation
  • Measured outcomes
  • Sustainability

Good to Verify Skills:

IIoT Implementation

Verification Method: Technical deep dive

Evaluation Criteria:
  • Sensor network design
  • Data analytics
  • Cloud integration
  • Cybersecurity
Project Management

Verification Method: Role-play exercise

Evaluation Criteria:
  • Planning
  • Resource allocation
  • Risk management
  • Stakeholder communication
Emerging Technologies

Verification Method: Research presentation

Evaluation Criteria:
  • Technology awareness
  • Innovation potential
  • Implementation strategy
  • Business impact analysis

Interview Preparation Tips

Research Preparation

  • Company automation systems
  • Industry trends
  • Competitor analysis
  • Technology stack

Portfolio Preparation

  • Select diverse projects
  • Prepare technical breakdowns
  • Include performance metrics
  • Showcase problem-solving

Technical Preparation

  • Practice PLC programming
  • Review control system design
  • Study industrial protocols
  • Refresh CAD software knowledge

Presentation Preparation

  • Develop case study templates
  • Prepare technical demonstrations
  • Anticipate design questions
  • Practice explaining complex concepts

Share interview prep