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5 Automation Technician Interview Questions and Answers

Automation Technicians are responsible for installing, maintaining, and troubleshooting automated systems and machinery. They work to ensure that these systems operate efficiently and effectively, often collaborating with engineers and other technical staff. Junior technicians focus on learning and performing basic maintenance tasks, while senior technicians may oversee complex installations, mentor junior staff, and contribute to system design improvements. Need to practice for an interview? Try our AI interview practice for free then unlock unlimited access for just $9/month.

1. Junior Automation Technician Interview Questions and Answers

1.1. Describe a time you diagnosed and fixed an intermittent PLC or sensor failure on a production line.

Introduction

Junior automation technicians need hands-on troubleshooting skills for PLCs, sensors, and actuators. This question assesses your practical problem-solving, familiarity with industrial control systems, and ability to work under production pressure—common expectations in Chinese manufacturing environments like Shenzhen electronics or automotive plants.

How to answer

  • Use the STAR framework: Situation, Task, Action, Result.
  • Start by describing the production context (type of line, shift impact, safety considerations).
  • Identify the symptoms you observed and how you narrowed down root causes (logs, I/O tests, multimeter, oscilloscope, swapping parts).
  • Explain specific diagnostic steps and tools you used (PLC ladder logic check, checking sensor alignment, wiring continuity, grounding, replacing modules).
  • Mention collaboration with colleagues or engineers if applicable and how you communicated risks to supervisors.
  • Quantify the result (reduced downtime, parts saved, faster cycle time) and any preventive steps you implemented (checklists, sensor guarding, updated documentation).

What not to say

  • Blaming vague causes like 'the machine was acting up' without evidence or methodical troubleshooting.
  • Saying you immediately replaced expensive parts without diagnosing, which suggests poor cost awareness.
  • Omitting safety actions or failing to mention lockout/tagout and operator notifications.
  • Taking sole credit if it was a team effort, or failing to mention follow-up preventive measures.

Example answer

On the night shift at a Shenzhen electronics assembly line, our pick-and-place station started missing components intermittently, causing line stoppages. I first recorded the PLC error codes and observed that the vacuum sensor reading fluctuated. After verifying air pressure and cleaning the suction nozzle, the problem persisted. I then checked the sensor wiring with a multimeter and discovered intermittent continuity on a connector due to vibration. I swapped the connector, re-routed the cable away from moving parts, and re-ran the cycle tests. Downtime dropped from three stoppages per shift to none over the next week. I logged the fix in the maintenance system and added a connector inspection to the daily checklist to prevent recurrence.

Skills tested

Troubleshooting
Plc Basics
Electrical Diagnostics
Attention To Safety
Communication

Question type

Technical

1.2. You arrive at the start of your shift and find a critical conveyor motor overheated and still running. What do you do, step by step?

Introduction

Situational response and safety judgment are crucial for junior technicians who must act quickly to protect people and equipment. This scenario tests your ability to follow safety procedures, prioritize actions, and coordinate with the team in a Chinese factory setting where production pressure is high.

How to answer

  • Start with immediate safety actions (stop the machine if safe, lockout/tagout).
  • Explain how you would notify the shift supervisor and operators and secure the area.
  • Describe diagnostic steps after ensuring safety (visual inspection, temperature source — motor driver, bearings, supply voltage).
  • Mention how you'd preserve evidence for root-cause analysis (logs, photos) and avoid making changes that hide problems.
  • Outline short-term remediation (cool down, replace or isolate motor) and longer-term follow-up (order spare part, update preventive maintenance schedule).
  • Emphasize adherence to company LOTO rules, PPE use, and communication with production planning to minimize impact.

What not to say

  • Turning power back on to test without proper checks, risking injury or further damage.
  • Ignoring management communication or failing to log the incident.
  • Attempting complex repairs alone when outside your authorization level.
  • Prioritizing production continuity over safety.

Example answer

First, I would stop the conveyor using the emergency stop and immediately apply lockout/tagout per company procedure, ensuring the motor cannot restart. I would cordon off the area and inform the line leader and shift engineer. After confirming it’s safe to approach, I would inspect the motor and driver for signs of burning, check the cooling vents and bearing condition, and use an infrared thermometer to confirm overheating source. I would document the state with photos and record machine logs. If the motor needed replacement, I would coordinate with maintenance to install a spare and update the CMMS entry. Finally, I'd communicate with production planning about the expected downtime and add a recurring inspection for that motor to the preventive checklist to avoid future overheating.

Skills tested

Safety Awareness
Incident Response
Communication
Basic Mechanical And Electrical Assessment
Documentation

Question type

Situational

1.3. What motivates you to build a career as an automation technician in China's manufacturing industry?

Introduction

Hiring managers want to know whether your motivations align with the realities of the role: hands-on work, continuous learning of PLCs/robots, shift work, and contributing to production efficiency. In China’s fast-growing automation sector, intrinsic motivation and a growth mindset predict long-term retention and performance.

How to answer

  • Be specific about what aspects of the job energize you (problem-solving, working with hardware/software, improving uptime).
  • Link your motivation to concrete experiences or influences (courses, internships, family background in manufacturing).
  • Show willingness to work shifts and learn new technologies (Siemens/Omron PLCs, FANUC/ABB robots).
  • Explain how you see your career progressing (senior technician, automation engineer) and how this role fits into that path.
  • Demonstrate cultural fit by acknowledging teamwork, discipline, and commitment typical in Chinese factories.

What not to say

  • Giving only generic answers like 'I need a job' or focusing solely on salary.
  • Saying you're not open to shift work or overtime common in manufacturing.
  • Claiming you prefer management roles immediately rather than learning technical skills first.
  • Suggesting you dislike repetitive tasks without showing how you handle them positively.

Example answer

I enjoy hands-on problem-solving and seeing immediate results from my work, which drew me to automation. During my vocational internship at a Shenzhen electronics plant, I assisted with PLC program tweaks and robot teach moves; I was excited by how small changes reduced defects and improved cycle time. I’m motivated to deepen my skills with Omron PLCs and basic robotics, handle shift responsibilities, and grow into a senior technician or automation engineer. I value teamwork and discipline on the shop floor and want to contribute to continuous improvement efforts to make production safer and more efficient.

Skills tested

Motivation
Career Orientation
Willingness To Learn
Cultural Fit
Resilience

Question type

Motivational

2. Automation Technician Interview Questions and Answers

2.1. A PLC-controlled packaging line has stopped intermittently during the night shift. Walk me through how you would diagnose and resolve the fault.

Introduction

Automation technicians must quickly diagnose PLC, I/O and field device issues to minimise downtime on production lines. This question tests practical troubleshooting, knowledge of PLC systems (Siemens/Allen-Bradley common in UK sites), safe working practices and communication with shift teams.

How to answer

  • Start with safety and immediate containment: confirm the area is safe, ensure machine is isolated if required, and inform supervisors/shift engineers.
  • Describe how you'd gather initial information: review PLC alarm history, HMI logs, SCADA/ historian events, and interview night-shift operators for exact symptoms and timing.
  • Explain systematic electrical and logical checks: verify power supplies, check key I/O status on the PLC, use online monitoring to view ladder/function block I/O states, and compare expected vs actual inputs/outputs.
  • Include field device inspection steps: visual check of sensors, actuators, connectors, fuses and terminal blocks; use a multimeter and clamp meter where appropriate.
  • Mention software-level diagnostics: check program changes/versions, look for recent deployments or communication errors (e.g., Profibus/Profinet, EtherNet/IP), and confirm HMI tags mapping.
  • Describe isolation and controlled tests: force I/O in a safe test mode, simulate sensor signals, swap suspected components if spares are available, and run single-cycle tests.
  • Detail how you'd implement a fix and validate: replace faulty hardware or correct PLC logic, run extended test cycles, monitor for recurrence across multiple shifts.
  • Finish with documentation and follow-up: log the fault, root cause, fix applied and any actions to prevent recurrence (e.g., sensor guard, preventive maintenance schedule), and communicate with maintenance team and production.

What not to say

  • Jumping straight to replacing expensive parts without any diagnostics.
  • Ignoring safety protocols (e.g., isolating equipment or lockout-tagout) to speed up testing.
  • Blaming operators or software vendors without presenting diagnostic evidence.
  • Describing only electronic checks without referencing PLC logic or software/communication issues.

Example answer

First I'd ensure the line is safe and communicate with the night supervisor. I'd collect alarm logs from the HMI/SCADA and ask operators for exact times and conditions of the stops. Online with the PLC I would monitor the I/O table to identify inputs failing at stop times. If an input bit is toggling unexpectedly, I'd inspect the associated sensor and its connector, verifying supply voltage and continuity with a multimeter. If the input is steady but the PLC output isn't actuating, I'd check the ladder logic and recent program changes, and test the output by forcing it in a safe mode. In a recent role at a Tier 1 automotive supplier in the UK I found an intermittent Ethernet switch causing sporadic Profibus timeouts; replacing the switch and updating the preventive check list eliminated the nighttime stops. I documented the fault, corrective action and updated the shift handover notes so operators could monitor for recurrence.

Skills tested

Plc Troubleshooting
Electrical Diagnostics
Logical Debugging
Safety Procedures
Communication

Question type

Technical

2.2. You are asked to commission a new robotic pick-and-place cell with incomplete documentation and a two-day deadline to get it running for a critical production batch. How would you approach this?

Introduction

Commissioning under time pressure is common in manufacturing. This situational question evaluates planning, risk assessment, prioritisation, ability to work with limited information, and safe, pragmatic delivery.

How to answer

  • Open with a quick risk and safety assessment: identify hazards, required PPE, and the need for lockout-tagout or a safe commissioning mode for robots.
  • Explain how you'd triage tasks: determine minimum viable commissioning scope to support the batch (critical functions vs non-essential features).
  • Mention stakeholder communication: notify production planners, engineering leads and suppliers about constraints and agree on acceptable scope/quality trade-offs.
  • Describe information-gathering actions: review available PLC/HMI code, check wiring diagrams, request missing drawings from OEM, and inspect mechanical alignment and end-of-arm tooling.
  • Outline an iterative commissioning plan: perform mechanical checks first, then electrical and cabling verification, basic power-up and homing, followed by dry-run cycle testing and finally live material tests.
  • Include contingency planning: identify spare parts, tools, and people (e.g., controls engineer, electrician) to call on; set go/no-go criteria and rollback plan in case of failure during the batch.
  • Emphasise documentation and handover: record configuration changes, safety interlocks, and known issues; schedule follow-up to complete full commissioning post-batch.

What not to say

  • Agreeing to proceed without checking safety interlocks or permitting a non-locked robot area.
  • Promising full functionality when clearly impossible in the time available.
  • Working in isolation without informing production or engineering leads.
  • Skipping dry runs and testing directly with live parts.

Example answer

I'd start by securing a safe commissioning plan and informing production that I'll be working on the cell. With only two days, I'd prioritise the minimum functions required for the batch: mechanical alignment, power-up, safety interlocks and a reliable pick/place cycle. I'd inspect wiring and compare available PLC logic to HMI behaviour, then perform homing and dry runs with the gripper. If a missing wiring drawing prevents progress, I'd contact the OEM for critical clarifications while continuing mechanical and safety checks. I'd set a contingency: if live trials fail after agreed attempts, we delay the batch with production planning's approval to avoid risk. After completing the minimum scope, I'd document temporary workarounds and schedule a full commissioning window. In previous work on a tight-line at a UK food-packaging site, this approach allowed us to run one production shift safely while we completed remaining tuning overnight.

Skills tested

Commissioning
Risk Management
Prioritisation
Stakeholder Communication
Robotics Basics

Question type

Situational

2.3. Describe a time you implemented a change that improved machine uptime or reduced defects. What was the change and how did you measure success?

Introduction

Continuous improvement is a key part of an automation technician's role. This behavioural/competency question assesses problem-solving, data-driven thinking, teamwork, and the ability to deliver measurable improvements.

How to answer

  • Use the STAR structure: Situation, Task, Action, Result.
  • Begin by describing the baseline problem and its business impact (downtime rate, defect rate, scrap cost).
  • Explain the diagnostic steps you took and how you identified root cause(s).
  • Detail the specific change you implemented (hardware, PLC logic, sensor repositioning, preventive schedule, etc.) and why you chose it.
  • Give quantitative results: percent uptime improvement, reduction in defects, time/cost savings and the time period measured.
  • Mention collaboration with colleagues (engineers, production, QA) and any follow-up steps or documentation you produced.
  • If possible, note lessons learned and how the solution was scaled or standardised across other lines.

What not to say

  • Giving vague outcomes like 'we improved uptime' without numbers.
  • Claiming sole credit for a team effort or omitting team collaboration.
  • Describing changes done without root cause analysis or proper testing.
  • Focusing only on technical detail without linking to business impact.

Example answer

At a Midlands electronics plant we had frequent misfeeds on a conveyor causing 6–8% line stoppages weekly. I investigated downtime logs, performed sensor signal analysis and found the photoelectric sensor was being blinded by dust accumulation and vibration misalignment. After verifying with forced I/O tests and operator observations, I repositioned the sensor, fitted a protective shroud and adjusted debounce settings in the PLC. I also added a daily simple visual check to the shift checklist. Over the next month downtime due to misfeeds fell from 6% to 1.5%, increasing throughput and saving around £8k/month in lost production. I logged the change in our CMMS and shared the fix with other lines that had similar sensors.

Skills tested

Continuous Improvement
Root Cause Analysis
Data-driven Decision Making
Teamwork
Documentation

Question type

Behavioral

3. Senior Automation Technician Interview Questions and Answers

3.1. Describe a time you diagnosed and fixed a repeat fault in an automated production line that was causing intermittent downtime.

Introduction

Senior Automation Technicians must quickly identify root causes of recurring faults in complex electromechanical and control systems to minimize production losses and prevent recurrence. This question evaluates troubleshooting depth, systematic diagnostic skills, and how you communicate and implement a durable fix.

How to answer

  • Use the STAR (Situation, Task, Action, Result) structure to keep the answer clear and chronological.
  • Start by describing the production environment (e.g., assembly line at a contract manufacturer, packaging line at a food plant), the business impact (downtime minutes/hourly loss), and frequency of the fault.
  • Explain the diagnostic steps you took: data collection (PLC logs, SCADA/HMI history, oscilloscope readings), reproducibility attempts, isolating mechanical vs. electrical vs. control logic causes.
  • Mention specific tools and protocols used (e.g., Siemens/Allen-Bradley PLCs, Modbus/EtherNet/IP troubleshooting, multimeter, insulation tester, vibration analysis).
  • Describe the root cause you identified (e.g., intermittent I/O module failure, encoder noise, loose terminal, PLC program race condition) and why other hypotheses were ruled out.
  • Detail the corrective actions you implemented: temporary containment to restore production and the long-term fix (hardware replacement, wiring re-termination, shielding, PLC logic change, updated preventative maintenance schedule).
  • Quantify the outcome: reduction in downtime, improved OEE, number of repeat incidents eliminated, and any cost savings.
  • Conclude with what you learned and any process changes you recommended (e.g., updated troubleshooting checklist, spare-parts policy, additional sensor diagnostics).

What not to say

  • Giving only high-level statements like "I fixed it" without steps or evidence.
  • Taking sole credit and ignoring team members, operators, or maintenance support.
  • Focusing only on software fixes when the problem was mechanical (or vice versa).
  • Claiming guesses without objective data or saying you didn’t document the fix or follow up.

Example answer

At a mid-sized food packaging plant using Allen-Bradley ControlLogix PLCs, we had an intermittent stop on the sealing line that occurred roughly twice per week and cost about $3,000 per stoppage. I gathered PLC error logs and correlated them with shift reports, then ran live diagnostics on the I/O rack and oscilloscope checks on the encoder signals. The fault appeared as sporadic lost encoder counts tied to a flaky digital input module; vibration and wiring checks pointed to a loose ribbon connector inside the control cabinet that loosened with equipment vibration. I implemented a temporary workaround by moving the encoder input to a redundant channel so production could continue, ordered a replacement module and redesigned the cable routing and strain relief. After installing the new module and securing cabling, the stoppages ceased; over the next three months we had zero repeat incidents and OEE for that line improved by 4%. I also updated the preventative maintenance checklist to include periodic connector torque checks. The systematic data-driven approach and follow-up documentation prevented recurrence.

Skills tested

Troubleshooting
Plc And Control Systems
Diagnostics
Electrical Testing
Root Cause Analysis
Documentation

Question type

Technical

3.2. You're scheduled to perform a major firmware update on robot controllers that requires a 4-hour line shutdown. A production manager asks you to shorten the outage to 2 hours because of a high-priority order. How do you handle this?

Introduction

This situational question assesses prioritization, risk management, stakeholder communication, and your ability to balance production demands with safety and quality when maintaining automation systems.

How to answer

  • Acknowledge safety and quality as non-negotiable, and explain the importance of following validated procedures for firmware updates.
  • Explain how you'd quickly gather facts: what exactly the update changes, rollback options, historical update durations, and whether a partial update or phased approach is viable.
  • Describe involving key stakeholders: production manager, quality, engineering, and IT/controls to assess the risk and possible mitigation.
  • Outline possible options with trade-offs: keep the full 4-hour window, split the update (e.g., update non-critical robots first), perform off-shift update, execute a tested rollback plan, or implement containment measures for the high-priority order.
  • State how you'd document the decision and obtain sign-off if a reduced window is chosen, and how you'd monitor closely post-update with predefined acceptance tests.
  • Emphasize communication: clearly set expectations, explain potential consequences of a rushed update (unplanned downtime, corrupted controllers), and commit to contingency planning.

What not to say

  • Agreeing to shorten the outage without assessing technical risks or consulting stakeholders.
  • Using overly technical jargon without explaining risks to non-technical stakeholders.
  • Refusing to be flexible without offering alternatives.
  • Failing to describe rollback or verification steps after the update.

Example answer

I would first explain to the production manager that firmware updates can introduce controller instability if not executed with proper rollback and validation, so safety and product quality are top priorities. Then I'd quickly review the release notes and past update duration to determine if any steps can be safely parallelized (e.g., pre-staging files, pre-checking backups, preparing acceptance test scripts). I'd convene a short meeting with production, QA, and controls/IT to discuss options: (1) keep the validated 4-hour window, (2) split the update by robot cell so the critical order can run on non-updated cells, or (3) perform the update during the next break/shift change. If we agree to reduce the window, I'd require formal sign-off after outlining the extra risk and ensure a tested rollback plan and post-update verification checklist are ready. That way we balance production demands with risk mitigation and ensure we can recover quickly if anything goes wrong.

Skills tested

Risk Management
Stakeholder Communication
Decision Making
Planning
Safety Compliance

Question type

Situational

3.3. Tell me about a time you coached a junior technician or operator to improve their troubleshooting skills on automated equipment.

Introduction

As a senior technician, mentoring less experienced staff increases team capability, reduces repeated callouts, and ensures faster incident resolution. This question evaluates teaching ability, communication, and how you transfer practical knowledge.

How to answer

  • Use a clear example and include the mentee's starting competence and the operational context (shift work, plant type).
  • Describe the learning objectives you set (e.g., interpret PLC ladder logic, use a multimeter, read motor nameplate data).
  • Explain the hands-on methods you used: shadowing, guided troubleshooting sessions, step-by-step checklists, and post-incident debriefs.
  • Highlight how you adapted your coaching to the individual's learning style and how you created safe opportunities for them to practice.
  • Provide measurable outcomes: reduced mean time to repair (MTTR), fewer repeat faults, certification completion, or increased autonomy.
  • Mention how you ensured knowledge retention (written procedures, runbooks, cross-training schedules).

What not to say

  • Saying you "told them what to do" without structured teaching or follow-up.
  • Taking sole credit for improvements without acknowledging the trainee's effort.
  • Describing a one-off training with no measured outcome or documentation.
  • Claiming you don't have time to mentor or that mentoring isn't part of the role.

Example answer

At a beverage bottling plant, we had a new hire operator who could run the line but struggled with diagnosing conveyor motor starters and simple PLC faults, which led to frequent calls to maintenance. I set a plan with three objectives: (1) read and interpret basic ladder logic for the main line PLC, (2) perform electrical checks safely using a multimeter and lockout/tagout (LOTO), and (3) execute a defined troubleshooting checklist for common faults. Over four weeks I paired with him on the night shift, guiding him through live troubleshooting, then gradually moved to a coaching role where he performed steps while I observed. I also produced a one-page troubleshooting reference and scheduled a knowledge check. Within six weeks his MTTR for first-level faults dropped by 35% and the number of maintenance callouts for simple issues decreased by half. He became the shift's go-to for initial diagnostics, freeing maintenance to focus on deeper issues. I documented the materials in our maintenance binder so the training could be repeated for future hires.

Skills tested

Mentorship
Communication
Training
Troubleshooting
Documentation

Question type

Behavioral

4. Lead Automation Technician Interview Questions and Answers

4.1. Describe a time you diagnosed and fixed a repeat PLC/interlock failure on a high-speed production line.

Introduction

As Lead Automation Technician in Japan's manufacturing environment, you must rapidly identify root causes in PLCs, safety interlocks, and servo systems to minimize downtime and meet strict production targets (common at Toyota, Fanuc-automated lines, etc.). This question assesses technical troubleshooting depth and ability to prevent recurrence.

How to answer

  • Start with a brief context: the production line type, product, and the frequency/impact of the failure (e.g., line stops per shift, lost output).
  • Describe how you gathered data: PLC logs, HMI alarms, oscilloscope traces, encoder/servo feedback, I/O status, and operator input.
  • Explain your diagnostic process step-by-step: isolate hardware vs. software, recreate the fault, run tests on modules (I/O, power supply, grounding), and verify parameter/config settings.
  • State specific technologies and tools used (e.g., Mitsubishi/Q-series, Siemens S7, Fanuc servo diagnostics, ladder logic, trace capture tools, multimeter, oscilloscope).
  • Detail the corrective action you implemented and why (code fix, firmware update, shielding/grounding correction, replacing a failing module, adding debounce or watchdog timers).
  • Describe preventive measures you put in place: updated SOPs, improved monitoring/alarms, spare-part strategy, test scripts, or design changes to eliminate recurrence.
  • Quantify results: reduced downtime minutes/hours per week, improved OEE, fewer unplanned stops, cost savings, and any follow-up verification period.

What not to say

  • Giving only high-level statements without concrete steps or tools used.
  • Claiming the fix was 'intuition' without demonstrating methodical diagnostics.
  • Taking sole credit and not acknowledging team members or operators who provided critical information.
  • Ignoring safety procedures or bypassing interlocks to test—implying risky behavior.

Example answer

At a midsize automotive parts plant in Osaka, our stamping line with a Mitsubishi PLC experienced three unplanned stops per shift from a safety interlock fault. I first collected PLC error logs and HMI alarm timestamps and matched them with operator shift notes. Using the PLC’s diagnostic tool I traced intermittent I/O dropouts to a single input card. I ran a bench test and reproduced the glitch when a nearby welding transformer powered up; the root cause was induced noise due to inadequate cable shielding and a marginal power supply on the I/O rack. I replaced the I/O module, re-routed and shielded the cables, and installed ferrite chokes. I also implemented an alarm that captured pre-fault input status and added a preventive maintenance check to test I/O card voltages weekly. Over the next three months the line stops dropped from 3 per shift to zero unplanned stops, improving OEE by 4% and saving the plant an estimated ¥1.2M annually in lost output.

Skills tested

Plc Troubleshooting
Electrical Diagnostics
Servo/encoder Knowledge
Root Cause Analysis
Preventive Maintenance
Communication

Question type

Technical

4.2. How have you led technicians and operators through a major line changeover or automation upgrade while keeping quality and schedule on track?

Introduction

A Lead Automation Technician must coordinate multidisciplinary teams (maintenance, production, engineering, quality) during upgrades or model changeovers common in Japanese factories. This evaluates leadership, planning, stakeholder management, and practical hands-on coordination.

How to answer

  • Outline the scope and business reason for the changeover or upgrade (new model, automation retrofit, production increase).
  • Describe the planning you did: timeline, resource allocation, risk assessment, critical-path tasks, and contingency plans.
  • Explain how you communicated with stakeholders: daily stand-ups, shift handovers, training sessions for operators, and sign-off criteria with quality/engineering.
  • Detail technical coordination: software version control, backup of PLC/HMI programs, simulation/testing schedules, and spare parts staging.
  • Share how you managed on-the-floor execution: supervising cutover steps, verifying safety and test runs, and addressing unexpected issues.
  • Give measurable outcomes: completed on schedule, reduction in defects, first-pass yield, reduced downtime, or lessons that improved future rollouts.

What not to say

  • Saying you 'delegated everything' without describing your active leadership role.
  • Underestimating the need for operator training or quality sign-off.
  • Ignoring cross-department communication or not involving engineering/QA early.
  • Failing to mention backup plans or how you mitigated risks when things went wrong.

Example answer

When our plant switched to a new electronic control unit model, I led the two-week automation upgrade affecting three assembly lines. I created a Gantt plan showing critical activities (PLC/HMI updates, sensor recalibration, jig adjustments) and held daily morning briefings with production, QA and engineers. I ensured we had current backups of all PLC code and implemented a stepwise test plan in a staging area. During the overnight cutover, we executed the plan in phases: physical installation, basic power-up checks, dry-runs, and then monitored first-parts with QA sign-off. I also ran short operator training sessions for the new HMI flows and posted troubleshooting cheat-sheets at stations. The upgrade finished on schedule with no quality rejects in the first 500 units and reduced setup time per changeover by 20%.

Skills tested

Project Coordination
Team Leadership
Stakeholder Communication
Planning
Quality Assurance

Question type

Leadership

4.3. Imagine one of your lines shows a small oil leak that could contaminate parts and risk product rejection. Production wants to keep running to meet quota. What do you do?

Introduction

This situational question evaluates decision-making under pressure, safety and quality prioritization, and ability to balance production targets with compliance—critical in Japanese manufacturing where quality standards are strict.

How to answer

  • Start by acknowledging the competing priorities: production targets vs. product quality and customer requirements.
  • Explain how you'd assess immediate risk: extent of contamination, affected product, risk of rework/rejection, and whether OEM/customer specs are violated.
  • Describe immediate actions: stop the affected process area if contamination risk is high, isolate the section, or implement a temporary containment while a controlled short pause allows repair.
  • Discuss communication: notify production supervisor, QA, safety officer, and maintenance; document the issue and decisions.
  • Describe how you'd expedite a fix and get the line back: quick repair steps, testing, verification by QA, and approval before resuming full production.
  • Explain how you'd prevent recurrence: root-cause analysis, revised maintenance schedule, operator checks, and updated SOPs.
  • Mention how you'd record the incident and any customer communication if necessary.

What not to say

  • Prioritizing production without considering quality or referring to bypassing quality checks.
  • Making unilateral decisions without informing QA/supervisors.
  • Suggesting an immediate full shutdown for minor, easily contained issues without risk assessment.
  • Failing to mention documentation and follow-up to prevent recurrence.

Example answer

I would first evaluate how much oil is contacting product—if any parts are at risk of contamination I would immediately isolate that machine and stop feeding parts into the suspect area. I would notify production, QA, and the safety officer and tag the machine out for maintenance. If the leak can be contained quickly (e.g., replace a seal and clean affected surfaces) I would arrange an expedited repair during a short planned pause and require QA to inspect first-run parts before full restart. If the leak created potential nonconforming parts already produced, I’d work with QA to quarantine and inspect those parts and log the incident per our PPAP/customer traceability requirements. After addressing the immediate issue, I’d lead an RCA to find the cause (e.g., degraded hydraulic seal, maintenance interval missed) and update the PM schedule and operator checklists to prevent recurrence. This preserves product quality and traceability while minimizing production loss.

Skills tested

Safety Awareness
Quality Management
Decision Making
Cross-functional Communication
Risk Assessment

Question type

Situational

5. Automation Engineer Interview Questions and Answers

5.1. Can you describe a project where you implemented an automation solution that significantly improved efficiency?

Introduction

This question assesses your practical experience with automation technologies and your ability to deliver measurable results, which is crucial for an Automation Engineer.

How to answer

  • Start by outlining the specific problem that needed addressing.
  • Describe the automation solution you designed or implemented and the technologies used.
  • Detail the implementation process, including any challenges faced and how you overcame them.
  • Quantify the improvement in efficiency and any other relevant metrics.
  • Share any long-term impacts this automation had on the team or organization.

What not to say

  • Focusing on theoretical knowledge without practical application.
  • Not providing specific metrics or results.
  • Downplaying the challenges faced during implementation.
  • Failing to mention collaboration with other teams or stakeholders.

Example answer

At Huawei, I led a project to automate our software testing process. We faced significant delays in our release cycles due to manual testing. I implemented a continuous integration system using Jenkins and Selenium, which reduced our testing time by 70%. This not only improved our release frequency but also enhanced the overall quality of our software. The success of this project reinforced the importance of automation in our workflow.

Skills tested

Problem-solving
Technical Expertise
Process Improvement
Project Management

Question type

Technical

5.2. How do you ensure the reliability and maintainability of the automation scripts you create?

Introduction

This question evaluates your understanding of best practices in software development and your commitment to long-term project sustainability, which is vital in automation.

How to answer

  • Discuss your approach to code quality, such as following coding standards and best practices.
  • Explain how you document your automation scripts for clarity and future reference.
  • Describe your testing strategies to validate automation scripts and ensure reliability.
  • Mention any tools or frameworks you use for version control and collaboration.
  • Highlight your approach to continuous improvement and updating scripts when necessary.

What not to say

  • Neglecting the importance of documentation and collaboration.
  • Assuming scripts don’t need to be updated once created.
  • Focusing solely on the immediate results without considering future maintenance.
  • Ignoring the importance of testing and validation.

Example answer

In my previous role at Tencent, I followed strict coding standards and utilized code reviews to maintain high quality in my automation scripts. I documented each script thoroughly, detailing its purpose and usage. To ensure reliability, I integrated automated testing using PyTest, which helped catch issues early. I also used Git for version control, allowing my team to collaborate effectively. This disciplined approach ensured our automation framework remained robust and maintainable over time.

Skills tested

Attention To Detail
Documentation
Testing
Teamwork

Question type

Competency

Similar Interview Questions and Sample Answers

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