In the workshop, a high-speed packaging line suddenly and frequently stalled. Senior engineer Wang
around the equipment to repeatedly check the PLC program, test sensors, compare mechanical parameters,
a few hours past is still at a loss. The newly recruited Zhang, but access to the production line real-time data
flow, combined with SCADA system history, within a few minutes to lock a hidden servo motor overload mode -
this is the traditional automation skills in the face of complex system failures typical dilemma. The field of
industrial automation is undergoing a profound change, mastering a single device operation and programming
is far from enough, and a new generation of engineers urgently need to build a composite skills ecosystem
integrating OT (operation technology) and IT (information technology).
Cornerstone Skills: The “Muscles and Nerves” of Automation Systems
No matter how the technology evolves, proficiency in the underlying physical system and core control logic is still the foundation:
In-depth control of PLC/DCS/SCADA:
Proficient in mainstream PLC (Programmable Logic Controller) hardware architecture, ladder diagram / LAD, function block
diagram / FBD, structured text / ST and other programming languages.
Understanding of DCS (Distributed Control System) hierarchical structure, configuration logic and complex loop control strategy.
Skillfully use SCADA (Data Acquisition and Monitoring System) for data visualization, alarm management, historical trend analysis
and basic remote operation.
Core value: This is the “nerve center” for precise equipment action and stable process operation, and the first line of defense for
fault diagnosis and optimization.
Sensors and actuators are “connected”:
In-depth understanding of various types of sensors (temperature, pressure, flow, position, vision, vibration, etc.) principle,
selection, installation and calibration and signal processing.
Proficient in all kinds of actuators (motors, inverters, servo drives, pneumatic/hydraulic valves, etc.) drive principles, control
interfaces (e.g. Modbus, CANopen, EtherCAT) and performance tuning.
Core value: Ensure that the system accurately senses the physical world and reliably executes control commands, which is
the “hands and feet” of automation.
Industrial network and communication “pulse”:
Master the principle, configuration and troubleshooting of mainstream industrial field buses (Profibus, Modbus RTU/TCP, CAN)
and industrial Ethernet protocols (Profinet, EtherNet/IP, EtherCAT, OPC UA).
Understand network topology, switch configuration, VLAN segmentation, and basic network security policies.
Core value: To ensure high-speed, reliable and safe transmission of data between devices and system layers, and to build the
“blood vessel” of interconnection.
Leapfrog Skills: Data-driven and Intelligent “Brain”
When the production line generates huge amounts of data, how to extract value from it and drive optimization and autonomous
decision-making becomes the key to winning in the future:
Industrial Internet of Things (IIoT) and Edge Computing “Tentacles”:
Master data acquisition (DAQ) technologies to efficiently connect various types of sensor and device data to IIoT platforms.
Understand the role of Edge Gateway and have the ability to pre-process, filter, aggregate and run lightweight models (e.g.
real-time anomaly detection) on the edge.
Core value: To bridge the “last mile” from the physical world to the digital world, providing real-time data fuel for intelligence.
Data analysis and visualization “insights”:
Skilled in using SQL to query industrial databases and master basic data processing and cleaning methods.
Ability to use Python (Pandas, NumPy) or specialized industrial analysis tools for data exploration, statistical analysis
(e.g. SPC control charts), correlation mining.
Proficient in data visualization tools (e.g. Grafana, Tableau, Power BI) or SCADA/HMI advanced functions to transform
complex data into intuitive insights.
Core Value: Recognize patterns in data noise, discover root causes, quantify improvements, and drive decisions.
Predictive Maintenance (PdM) and Process Optimization “Prophet”:
Understand equipment failure mechanisms and the principles of common predictive maintenance techniques such as
vibration analysis, fluid analysis, and thermal imaging.
Interpret and apply machine learning models (e.g., timing prediction, anomaly detection) to predict equipment health
status (RUL).
Master data-based process parameter optimization methods and understand how to use model recommendations to
improve yield and reduce energy consumption.
Core Value: Turn reactive into proactive, maximize equipment utilization, continuously optimize production
process, and reduce costs.
Systems Integration and Digital Twin “Mapping”:
Ability to integrate PLC/DCS, SCADA, MES (Manufacturing Execution Systems), IIoT platforms and even ERP
(Enterprise Resource Planning) at the data and application level (e.g. API calls, middleware applications).
Understand the basic concept and value of Digital Twin, be able to participate in building virtual models of production
lines or key equipment, and understand the application of simulation in optimization and forecasting.
Core Value: Break down information silos, build virtual-reality mapping, realize global optimization and
forward-looking decision-making.
Integration Skills: The “glue” for communication, collaboration and continuous learning.
With the rapid iteration of technology, cross-domain collaboration has become the norm, and soft skills are indispensable:
Cross-discipline communication “bridge”:
Be able to explain IT requirements (e.g., data interfaces, network security) in terms that OT engineers understand, as well
as clearly articulate the logic and physical constraints of production line control to IT colleagues.
Communicate effectively with operators, maintenance staff, process engineers, and management, and understand the pain
points and goals of different roles.
Core Value: Ensure that intelligent projects are implemented accurately and avoid “technology silos”.
Systematic thinking and problem solving “compass”:
Analyze problems from a global perspective, understand the interplay between equipment, process, control, and data, and avoid “headache”.
Skillful use of root cause analysis (RCA) methods (such as 5Why, fishbone diagram) to solve complex system failures.
Core Value: Efficiently locate and solve deep-rooted problems to improve system reliability and resilience.
Continuous learning and adaptive “engine”:
Maintain a high degree of sensitivity and willingness to learn new protocols (e.g., TSN time-sensitive networks), new tools (e.g.,
low-code platforms), and new ideas (e.g., Industry 5.0 human-oriented).
CORE VALUES: Maintain core competencies in a fast-changing industrial environment to stay ahead of the times.
Build your skill map: from specialization to integration
The evolutionary path of an industrial automation technician is clear:
Beginner: Deepen the “cornerstone skills” such as PLC programming, equipment maintenance, network foundation, etc. to become a
reliable problem solver.
Growth: Expand “leapfrog skills” such as IIoT, data analytics, system integration, etc., and transform into data-driven engineers.
Maturity: Strengthen predictive maintenance, process optimization, digital twin applications, and become proficient in “convergence
skills” to become a cross-discipline project leader or solution architect.
The battle for the factory of the future is essentially a battle for talent skill mapping. When the cold steel and precise code are given
the ability of data insight and intelligent decision-making, the core of driving all of this is the engineers' continuous iteration and
upgrading of the knowledge system and practical wisdom. From twisting screwdrivers to interpreting data models, from debugging
relays to building digital mirrors - the boundaries of industrial automation technology skills are being reshaped. By mastering the
skills map that integrates OT and IT, connects physical and digital, and has both depth and breadth, we can truly become the core
engine driving intelligent manufacturing, and stand at the forefront of the wave of Industry 4.0.