Manufacturing Engineer – ABB Robotics Programming

ARi, headquartered in East Peoria, IL, USA, is a rapidly expanding global engineering enterprise. With a diverse team of over 1,500 engineering experts from various nations and cultures, we provide intricate and personalized resolutions to our esteemed clients.

About the role

The Manufacturing Engineer – Robotics Programming will provide hands-on technical support and leadership for robotic automation systems within a manufacturing environment. This position will focus heavily on ABB robot programming, troubleshooting, system integration, program optimization, commissioning, and continuous improvement. The engineer will support production-critical robotic applications across engine assembly, testing, and paint operations and work closely with Controls/PLC, Manufacturing, Maintenance, Quality, and Production teams to improve equipment reliability, safety, quality, and throughput.

Responsibilities

• Program, configure, troubleshoot, and commission ABB industrial robots and robotic work cells.
• Provide hands-on, shop-floor troubleshooting and issue resolution for ABB robotic applications supporting engine assembly, test, and paint operations.
• Diagnose and resolve production downtime related to robots, controls, tooling, sensors, cabling, and other automation equipment.
• Develop, modify, and optimize ABB robot programs for new and existing manufacturing processes.
• Analyze previous incidents and production observations to identify opportunities for robotic program optimization and permanent corrective actions.
• Optimize existing robot configurations, including harnesses, cabling, end-of-arm tooling (EOAT), and associated equipment.
• Integrate robotic systems with PLCs, vision systems, sensors, conveyors, tooling, and other peripheral equipment.
• Partner closely with PLC/Controls Engineers to troubleshoot automation issues, determine root causes, and implement permanent resolutions.
• Lead and support robotic system validation, testing, startup, and commissioning activities.
• Perform root cause analysis and implement corrective actions for recurring robotic and manufacturing issues.
• Drive continuous improvement initiatives focused on cycle time, OEE, equipment reliability, safety, and product quality.
• Develop and maintain standard work instructions, troubleshooting documentation, training materials, and operating procedures.
• Collaborate with Manufacturing, Controls, Quality, Maintenance, Product Engineering, and Production teams to resolve manufacturing challenges.
• Provide independent technical support for production-critical robotic systems with a strong focus on minimizing downtime.

Requirements

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, Mechatronics, Robotics, or a related engineering discipline.
• Minimum 5+ years of industrial robotics and manufacturing automation experience required; candidates with approximately 5–10 years of relevant experience are preferred.
• Significant hands-on experience programming and troubleshooting ABB industrial robots is required.
• Must be comfortable maintaining a strong shop-floor presence and independently supporting production-critical robotic systems.

Skills

• Extensive hands-on experience with ABB industrial robot programming and troubleshooting.
• Strong working knowledge of ABB RobotStudio and ABB robot controller platforms.
• Strong robotic troubleshooting and manufacturing automation experience.
• Ability to diagnose robot faults and resolve production-critical automation issues directly on the manufacturing floor.
• Experience developing, modifying, debugging, and optimizing robotic programs.
• Experience with robotic applications such as arc welding, material handling, assembly, machine tending, paint operations, or other automated manufacturing processes.
• Experience integrating robotic systems with PLCs, including Allen-Bradley, Siemens, or equivalent platforms.
• Understanding of robot interfaces with sensors, tooling, conveyors, safety systems, and peripheral equipment.
• Experience troubleshooting and optimizing robot hardware configurations, including harnesses, cabling, and end-of-arm tooling.
• Strong understanding of manufacturing processes, Lean principles, root cause analysis, and continuous improvement methodologies.
• Ability to work independently in a fast-paced manufacturing environment and support critical production issues.
• Strong communication, teamwork, and cross-functional problem-solving skills.

Preferred Skills

• Experience with vision-guided robotics and automated inspection systems.
• Experience commissioning new robotic automation equipment and production lines.
• Knowledge of industrial networking and communication protocols.
• Six Sigma, Lean Manufacturing, or similar continuous improvement experience.
• Experience supporting high-volume manufacturing operations.
• Experience supporting robotic applications within engine, automotive, heavy-equipment, or similar manufacturing environments.

Schedule

Must be available to work either 1st shift (6:00 AM–3:00 PM EST) or 3rd shift (10:00 PM–6:00 AM EST) onsite in Lafayette, Indiana.