Advanced Controls and Robotics Technician - Welding Cells

Build what’s next in automated welding

Step into a senior hands-on role where production uptime, quality welds, and operator safety all depend on your expertise. You’ll support, program, and troubleshoot complex robotic welding systems while growing others through mentorship.

Core impact

• Lead setup, operation, and troubleshooting of automated welding cells across multiple applications.
• Coach Automation Technician I & II and Weld Technicians; model best practices and safe work habits.
• Diagnose electrical/mechanical issues using prints and schematics; repair circuits and components (harnesses, drives, relays, boards, motors, breakers, transformers).
• Perform intermediate robot programming and optimization: offline edits (RoboCAD/RobotStudio), TCP checks, I/O simulation, move and zone adjustments.
• Resolve weld issues across drawn arc, GMAW, resistance, projection, and pneumatic systems.
• Operate precision instrumentation: hand measuring tools, amp and weld current meters, digital force gauges, micro‑ohm meters.
• Execute fixture refinements and minor shim moves per manufacturing details with guidance from a Weld Maintenance Mechanic III or Manufacturing Engineer; apply proper shimming techniques.
• Install, configure, and troubleshoot poka‑yoke systems.

Specialize and lead in one track

Controls

• Intermediate PLC programming (add sensors, modify sequences); ladder logic troubleshooting.
• Program/troubleshoot PanelView (HMI); set up I/O blocks; search, cross‑reference, and edit programs; load programs.
• Replace/commission control components; set IP addresses and system names.
• Troubleshoot valve stacks and associated pneumatics/electrics.

Robotics

• Intermediate robot programming methods, including offline routine creation.
• Load IDs, tune guns, and add system components (valves, I/O blocks).
• Set up and troubleshoot tool changers and external axes.
• Create/verify TCP (ABB Bullseye a plus), build offsets, and replace motors/resolvers/serial pulse coders.

Welding

• Intermediate weld troubleshooting and specialty equipment PM.
• Rebuild/reload schedules and implement Weld Engineer‑directed changes (RAFT, Emhart DA, MIG).
• Perform cap/electrode studies, weld validation, and spot gun squeeze force calibration.
• Troubleshoot drawn arc stud welding (with basic programming) and projection weld setups.
• Apply working knowledge of the Miyachi Weld Tester.

How you work

• Read job element sheets; interpret mechanical/electrical prints with accuracy.
• Use gauges and hand tools correctly; apply multimeters, amp/weld current meters, force gauges, and micro‑ohm meters.
• Follow Challenge’s safety policies; drive root‑cause problem solving.
• Show integrity, reliability, and a team‑first approach while flexing to support plant flow.
• Prioritize effectively, communicate clearly, and hand off thoroughly to the next shift.
• Embrace change and continuous improvement; resolve conflicts objectively and constructively.

Qualifications

• High school diploma or equivalent.
• Industrial truck and aerial platform licenses.
• Excellent verbal communication and PC skills (Word, Excel, Outlook).
• Successful completion of Automation Technician II written and performance tests (internal and external candidates).
• Knowledge of PLC systems with intermediate programming capability.
• Industrial Maintenance/Machine Repair/Electrician Journeyman certification, or 2‑year technical degree, or equivalent experience.
• Minimum 3 years of experience as a Weld Technician, Automation Technician, or equivalent.
• Preferred: Mechatronics certificate or journeyperson card; Associate’s in mechatronics/controls/maintenance technology; 6+ years combined education/experience in automation; strong electrical and mechanical background in industrial/automated systems.

Technical strengths

• PLC troubleshooting and programming
• Electrical schematics and installation
• Industrial robot programming
• Troubleshooting industrial automation equipment
• Programming machine vision systems
• Electrical/electronic systems
• Pneumatics troubleshooting

Equipment and platforms

• Robotic welders
• PLCs (Fanuc)
• Industrial robots (Fanuc, ABB)

Physical and schedule requirements

• Lift/move up to 60 lbs.
• Work up to 12 hours per day, including Saturday and Sunday.
• Consistent attendance; ensure coverage when absent.
• Read, understand, and follow written and verbal instructions.