Describe a situation where you had to troubleshoot a complex automation-related issue. What steps did you take to resolve it?

Oh, there was this one time at my last job where we were dealing with a tricky automated assembly line glitch. It kept misaligning parts, you know. So, I started fixing it by just breaking down the problem. Checked the sensors first, they seemed okay. Then I moved to the software, updated some old code that seemed to smooth things over. But, it wasn't just that, the actuator was acting up too, so I recalibrated that bad boy and, voil, no more misaligned parts!

On my previous team, we had an instance where our robotic painting system started to apply uneven coatings. This was a critical issue, impacting product quality. Step one was to gather all available data logs for analysis. I sat down with our software engineers to review recent updates and their implications on the system's performance. Once we identified a few potential causes, I led a cross-discipline troubleshooting session, involving mechanical and software engineers. We simulated the conditions and pinpointed a fault in the motion control algorithm, combined with a calibration drift in our painting robots. My contribution involved coding a patch and orchestrating a recalibration routine, effectively solving the issue and documenting the solution for future reference.

In a previous position as an Automation Engineer, we once faced an intricate challenge when our high-speed packaging system's efficiency plummeted. My first move was to conduct a meticulous analysis of the anomaly reports and system logs. After consulting with the team, we isolated the issue to a recent software update and a malfunctioning servo motor. By leveraging my in-depth knowledge of C++ and Python, I personally developed a diagnostic script to monitor system performance, isolating inefficiencies. Furthermore, during a brainstorming session I led, we innovated a predictive maintenance model using machine learning techniques adapted from a project I spearheaded beforehand. This not only rectified the immediate problem but improved overall system resilience. Post-resolution, I conducted workshops with junior staff to disseminate the processes we had implemented, ensuring the knowledge was embedded within our team.