What issues have you encountered when programming PLCs, robotics, or other automated control systems, and how did you overcome them?

Sample answer to the question

Oh, programming PLCs and whatnot comes with its challenges, for sure. Just the other week, I was syncing a new conveyor belt system with legacy hardware, and ran into issues where the old communication protocol was clashing with the new setup. What I did was dive into the manufacturer's manuals, you know, those thick tomes that nobody enjoys, dusted it off, and eventually unraveled the mystery. With this discovery, I reworked the interface and got the systems to play nice. It was a bit of a headache but, hey, that's part of the job!

A more solid answer

In my career as an Automation Engineer, I've come across various issues, especially when interfacing new robotic systems with older PLCs. Recently, during the integration of an advanced robotic arm into our existing assembly line, I encountered a synchronization error between the arm's software and the legacy PLCs. To resolve this, I conducted a thorough analysis using my knowledge of Python and Java and developed a custom middleware. This helped to translate commands seamlessly. I also had to analyze the network protocols and reconfigure the communication parameters to ensure proper data flow. It was a complex task that required careful planning, but through teamwork and clear communication, we overcame the obstacle.

Why this is a more solid answer:

This solid answer expands upon the basic one by adding specificity related to programming languages and discussing analytical techniques used to solve the problem. Additionally, it implies communications and teamwork required for project integration. However, it could still provide more detail on the project management aspect and the analytical process undertaken.

An exceptional answer

As an avid Automation Engineer with a knack for problem-solving, I've encountered a myriad of issues, but one that sticks out involved integrating a high-precision robotic painting system into an automotive manufacturing line. The challenge was twofold: an incompatibility between the robot's modern protocols and the factory's aged PLC network, and a significant variation in the performance of the system during live runs versus simulations. Leveraging my strong programming background in C++ and Python, I designed a robust protocol converter to enable seamless communication. Furthermore, careful analytics led me to modify the painting algorithm for dynamic environmental factors, substantially improving consistency. Throughout, I maintained a transparent communication channel with the team and meticulously documented every step for ongoing maintenance and future reference, exemplifying project management best practices.

Why this is an exceptional answer:

The exceptional answer covers all evaluation areas in depth. It showcases a clear use of programming skills, understanding of protocols, and project management through thorough documentation and team communication. It also provides specific examples, which demonstrate a strong analytical approach and the ability to handle real-world variation in automated systems.

How to prepare for this question

Reflect on specific instances where your problem-solving skills particularly shone through a complex project, and articulate how you resolved those issues.
Clarify your programming experience by pinpointing particular languages or tools you used and how they contributed to successful outcomes in your work.
Review common industrial networks and communication protocols and be prepared to discuss how you have worked with these in previous roles.
Gather examples where you have successfully integrated automation solutions into existing systems, focusing on your strategies and the results.
Brush up on your project management experiences and be ready to narrate how you steered a project from conception to completion, dealing with any issues that arose.

What interviewers are evaluating

Strong analytical and problem-solving skills
Excellent programming skills in languages such as C++, Python, or Java
Knowledge of industrial networks and communication protocols
Experience with integrating automation solutions into existing industrial systems
Proven ability to manage automation projects from conception through to completion