Senior Robotic Welding Automation Technician

A day in the life

You start your shift by checking on a bank of robotic welding cells. A quick scan of HMI screens, a few pages of electrical prints, and you’re inside a control panel verifying I/O. A Weld Technician flags a quality concern; you dive into ladder logic, simulate the I/O, verify TCP, and make a small move adjustment offline in RoboCAD/RobotStudio. Before lunch, you’re mentoring an Automation Technician I on shimming a fixture. By afternoon, you’re tuning a gun, validating a MIG schedule per Weld Engineering direction, and coaching a Technician II through a PanelView screen replacement. You wrap with a handoff to the oncoming shift so production keeps flowing.

What you’ll own

• Provide hands-on production support for automated welding cells: setup, safe operation, troubleshooting, and optimization.
• Mentor Automation Technician I & II and Weld Technicians; set the standard for safety, quality, and urgency.
• Apply advanced troubleshooting using mechanical/electrical prints and schematics to diagnose components and circuits, including wiring harnesses, drives, relays, boards, motors, breakers, and transformers.
• Modify and perform intermediate robot programming across applications: basic offline edits (RoboCAD/RobotStudio), TCP verification, I/O simulation, move creation/modification, and zone configuration.
• Diagnose weld processes (drawn arc, GMAW, resistance, projection, pneumatic systems) and perform intermediate corrective actions.
• Use precision tools safely at an advanced level: hand measuring tools, amp meters, welding current meters, digital force gauges, and micro-ohm meters.
• Perform fixture tweaks and minor shim moves per manufacturing details with guidance from a Weld Maintenance Mechanic III or Manufacturing Engineer; apply sound shimming practices.
• Configure and troubleshoot poka‑yoke systems to prevent defects.

Choose and demonstrate strength in one specialty

Controls

• Intermediate PLC programming: add sensors, alter sequences, and troubleshoot via ladder logic.
• Program and troubleshoot PanelView (HMI), set up/troubleshoot I/O blocks, search/cross‑reference/edit programs, load programs.
• Replace/commission components (logic modules, screens), set IP addresses and system names.
• Troubleshoot valve stacks and related control hardware.

Robotics

• Apply intermediate robot programming methods, including offline routine creation.
• Load IDs, perform gun tuning, add system components (valves/I/O blocks).
• Set up/troubleshoot tool changers and external axes.
• Create/verify TCP (ABB Bullseye experience is a plus), create offsets, and replace motors, resolvers, and serial pulse coders.

Welding

• Execute intermediate weld troubleshooting and preventive maintenance on specialty equipment.
• Rebuild/reload schedules and make changes directed by Weld Engineers (RAFT; Emhart DA; MIG).
• Conduct cap/electrode studies and weld validation; calibrate squeeze force on spot guns.
• Troubleshoot drawn arc stud welding and perform basic programming; set up/troubleshoot projection welds.
• Leverage working knowledge of the Miyachi Weld Tester.

What you bring

• Fluency with job element sheets; ability to interpret mechanical/electrical prints.
• Proficiency with gauges (functional, go/no‑go), hand tools, multimeters, amp/weld current meters, force gauges, and micro‑ohm meters.
• Commitment to Challenge’s safety policies and procedures; strong root‑cause mindset.
• Solid understanding of welding processes and automated manufacturing.
• PC literacy (keyboard/mouse); Microsoft Word, Excel, Outlook.
• Team-first mindset, high personal standards, integrity, and reliability.
• Self‑motivated, able to prioritize, receive and apply feedback, and resolve conflicts constructively.
• Flex across work areas to support plant flow; work with urgency to meet customer needs.
• Change‑ready outlook; treat new methods as opportunities to learn.
• Clear communication with supervisors and thorough shift‑to‑shift handoffs.

Qualifications

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

Proficiencies

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

Tools and technology

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

Work environment

• Ability to lift/move up to 60 lbs.
• Ability to work up to 12 hours per day, including Saturday and Sunday.
• Reliable attendance and ensuring coverage when absent.
• Ability to understand and follow written and verbal instructions.