58 Occupational Outlook Quarterly • Spring 2010

John Mullins

John Mullins is an 

economist in the 

Office of Occupational Statistics 

and Employment 

Projections, BLS. 

He can be reached 

at (202) 691–6547 

or mullins.john@

bls.gov.

Many people think of automation as 

laborsaving technology. But it sure 

keeps Jim Duffell busy. 

Jim is an automation technician. For the 

past 9 years, he has spent his workdays monitoring production equipment for a food manufacturing company in San Antonio, Texas. 

The company’s products—mixes for biscuits, 

enchiladas, and gravy—are manufactured 

using fairly typical automation processes.

Defined simply, automation is a technique 

for making a device run or a process occur 

with minimal direct human intervention. But 

the functions and technologies involved in 

automated manufacturing are complex. Nearly 

all functions, from orders coming in to products going out, are subject to automation. The 

technologies include mechanical, electrical, 

and computer, among others. 

And it is the job of automation technicians like Jim to monitor, troubleshoot, and 

repair these complex systems. “I go from one 

piece of equipment to another,” says Jim. “I’m 

on my feet most of the day.”

In the company where Jim works, ingredients for the mixes are blended, stored, and 

packaged by machines that are controlled by 

computerized devices. These devices, known 

as programmable logic controllers, regulate the weight and quantity of ingredients, 

transmission of mixes to storage areas, and 

packaging and shipment of final products. 

Additionally, customer order information is 

automated to reduce excess inventory. 

When production runs smoothly, Jim 

concentrates on preventative maintenance and 

upkeep. He uses a variety of instruments to 

ensure that all equipment is operating within 

a given tolerance, or range. For example, he 

may use standardized weights to make certain 

that the appropriate amount of each ingredient 

in the biscuit mix is being dispensed.

If part of the process isn’t working 

correctly it can be an alarming experience—

literally. When a piece of equipment begins 

functioning outside its assigned tolerance, 

an alarm sounds. A first alarm makes Jim 

aware of a problem but allows production to 

continue while Jim goes through a logical 

sequence to isolate, and fix, the problem. He 

must complete this process before a second 

alarm sounds, which indicates a more severe 

problem and shuts down production. Many 

manufacturing companies operate 24 hours 

a day. Shutdowns are costly, so automation 

technicians must be able to identify and solve 

problems quickly. 

Automation technicians may have a 

variety of job titles, depending on their 

specific duties and the industry in which they 

work. Jim’s title is “lead production support 

technician.” Other common titles include 

“control technician” and “instrumentation 

technician.” But whatever they are called, 

automation technicians need certain skills to 

perform their jobs.

Critical thinking and problem-solving 

skills are a must, as is the ability to work 

well under pressure. Automation technicians 

are sometimes asked to prepare reports for 

managers or other nontechnical audiences, so 

they should be able to write well. And because 

their job may involve training junior staff, automation technicians need good interpersonal 

and communication skills. “Nine times out of 

ten, the work I’m doing is more complicated 

than the trainees have been prepared for,” says 

Jim. “It’s my job to explain the information in 

a way that’s clear enough for those new to this 

work to understand.” 

Above-average proficiency in computers 

is also critical for these technicians, because 

much of their job involves minor programming. And nearly all automation technology 

You’re a what?

Automation technician
Spring 2010 • Occupational Outlook Quarterly 59

involves measurement, so aptitude in mathematics is important.

Many automation technicians have a 

background in either mechanics or electronics. Jim, for example, started out as a maintenance electrician for another food manufacturer. There, he learned programmable logic 

controller electronics—and when that company downsized, Jim’s knowledge gave him 

an edge in applying for his current position.

Like Jim, many automation technicians 

build their skills through years of on-the-job 

training. But that training is usually supplemented with additional preparation, such as 

completing certification programs that are 

conducted by producers of automation equipment. Jim has completed four such courses 

related to equipment he oversees at work. 

Jim advises prospective technicians today 

to get a postsecondary degree. “It’s possible 

to get a job if you have a lot of experience,” 

he says, “but these days, most companies are 

looking for people with an associate degree.” 

That advice is echoed by industry sources, 

who stress the importance of education. 

Some institutions offer training specifically in 

automation technology, and many others offer 

coursework that can be tailored to duplicate 

such programs. Two-year programs are available at some community colleges. Vocationaltechnical schools, unions, and industry trade 

associations also offer training. 

Formal training should cover four basic 

areas: mechanics, electronics, computer 

science, and process control. These disciplines—known together as mechatronics—

are the core of automation technology.

The U.S. Bureau of Labor Statistics 

(BLS) does not collect employment or wage 

data on automation technicians. Industry 

sources suggest, however, that the annual 

wage is about $50,000, an amount similar to 

the May 2008 wage for closely related engineering technician occupations for which BLS 

does collect data. The annual median wage for 

U.S. workers across all occupations in May 

2008 was $32,390.

Jim’s job can be demanding; he’s often 

required to put in overtime and to be on call. 

But he finds his work gratifying. “Every day, 

there’s a different challenge,” he says, “and 

every day I learn something.”

Automation technicians 

monitor, troubleshoot, 

and repair complex 

manufacturing systems.