Programming & Controls

Getting Started

Entry Point: Most automation technicians start with a 2-year associate degree in industrial automation, mechatronics, or electrical technology. Some enter through electrical apprenticeships.

First Steps: Master ladder logic (Allen-Bradley RSLogix or Siemens TIA Portal). Learn basic electrical troubleshooting. Understand sensors, actuators, and I/O systems.

Key Insight: Automation is about systems thinking. You need to understand how electrical, mechanical, and software components work together.

Prerequisites

• Math: Algebra, basic trigonometry
• Electrical: Basic DC/AC theory, understanding of circuits
• Logic: Ability to think sequentially, troubleshoot systematically
• Computer: Comfortable with software, file management

Background Helpful: Electrical experience, mechanical aptitude, or programming exposure.

Timeline

• 6 months: Basic ladder logic, simple programs
• 1-2 years: Associate degree, entry-level technician
• 3-5 years: Multi-platform proficiency, HMI development, system integration
• 5+ years: Controls engineer, system designer, lead automation specialist

Reality Check: Most technicians become productive within 6-12 months.

Time Investment

Associate Degree: 2 years (60-70 credits, ~20 hours/week)

Certificate Programs: 6-12 months focused on PLC programming

Manufacturer Training: 1-2 weeks per platform (Allen-Bradley, Siemens, etc.)

On-the-Job: 6-12 months to become fully productive

Continuing Education: 40-80 hours/year for new platforms and technologies

Costs

Associate Degree: $3,000-$15,000 (community college) to $25,000+ (technical college)

Certificates: $2,000-$5,000 for focused PLC training

Software Licenses: Often provided by employer; student versions $100-$500

Tools: $500-$1,500 for multimeter, laptop, basic hand tools

ROI: Median salary $70K; senior automation specialists earn $90K-$120K+

Equipment & Tools

• Laptop: Windows-based, 16GB RAM for PLC programming software
• Multimeter: Fluke 87V or equivalent ($300-$500)
• Software: RSLogix (employer-provided), TIA Portal (Siemens, free trial)
• Training PLCs: Many schools have Allen-Bradley MicroLogix or CompactLogix

Note: Most employers provide software licenses and specialized tools.

Manufacturing

Production lines, material handling, quality control. Every factory needs automation.

Water Treatment

SCADA systems, pump control, chemical dosing. Municipal and industrial facilities.

Food & Beverage

Packaging lines, batch control, traceability. FDA compliance requirements.

Oil & Gas

Refinery control, pipeline monitoring, safety systems. High-stakes, high-pay.

Pharmaceutical

Batch processing, cleanroom automation, validation. GMP compliance critical.

Building Automation

HVAC, lighting, security systems. Growing field with IoT integration.