Senior Mechatronics Specialist, Weld Automation

Are you the go-to expert when a robot won’t weld right?

If you thrive on solving hard problems at the intersection of controls, robotics, and welding—and enjoy teaching others how to do the same—this role is for you.

What you’ll do

• Keep automated welding cells running at peak performance through safe setup, operation, troubleshooting, and continuous improvement.
• Mentor Automation Technician I & II and Weld Technicians; elevate team capability and adherence to best practices.
• Trace faults using electrical/mechanical prints and schematics; repair and commission circuits and components such as harnesses, drives, relays, boards, motors, circuit breakers, and transformers.
• Execute intermediate robot programming: offline routine changes (RoboCAD/RobotStudio), TCP verification, I/O simulation, move edits, and zone setup.
• Diagnose and correct issues in drawn arc, GMAW, resistance, projection, and pneumatic welding systems.
• Operate precision measurement and diagnostic tools: hand measuring tools, amp meters, weld current meters, digital force gauges, micro‑ohm meters.
• Perform fixture adjustments and minor shimming per manufacturing details with guidance from a Weld Maintenance Mechanic III or Manufacturing Engineer; understand shimming principles.
• Implement and troubleshoot poka‑yoke devices to prevent defects.

Demonstrate mastery in one pathway

Controls : Intermediate PLC programming (add sensors, change sequences), ladder logic troubleshooting, PanelView (HMI) programming and issue resolution, I/O block setup, program search/cross‑reference/edit, program loading, component replacement/commissioning, IP address and system name configuration, and valve stack troubleshooting.

Robotics : Intermediate robot programming methods, ID loading, gun tuning, adding system components (valves/I/O blocks), offline routine development, setup/troubleshoot tool changers and external axes, TCP creation/verification (ABB Bullseye plus), creating offsets, and replacing motors/resolvers/serial pulse coders.

Welding : Intermediate weld troubleshooting, specialty equipment PM, rebuild/reload schedules, Weld Engineer‑directed changes (RAFT, Emhart DA, MIG), cap/electrode studies and weld validation, spot gun squeeze force calibration, drawn arc stud welding troubleshooting/basic programming, projection weld setup/troubleshooting, and use of the Miyachi Weld Tester.

How you operate

• Read job element sheets; accurately interpret mechanical/electrical prints.
• Use gauges, hand tools, multimeters, amp/weld current meters, force gauges, and micro‑ohm meters correctly.
• Follow Challenge’s safety procedures; drive to root cause and corrective action.
• Demonstrate integrity, reliability, and teamwork; flex across departments to maintain plant flow.
• Prioritize autonomously; communicate clearly with supervisors and the oncoming shift.
• Seek feedback, resolve conflict constructively, and embrace change as a learning opportunity.

Qualifications

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

Technical toolkit you already have

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

Platforms you’ll touch

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

Physical and scheduling expectations

• Lift/move up to 60 pounds.
• Work up to 12 hours per day, including Saturday and Sunday.
• Maintain dependable attendance; arrange coverage when absent.
• Understand and follow written and verbal instructions.