Robotic Weld Engineer

Primary Job Focus

This role is heavily focused on robotic weld programming, weld process development, and weld quality optimization. Candidates must bring strong hands-on experience in robotic welding systems and weld parameter development.

Key Responsibilities

• Develop, program, and optimize robotic welding applications (e.g., FANUC, ABB, Yaskawa/Motoman, KUKA)
• Perform robot teach pendant and/or offline programming for new and existing weld processes.
• Establish and validate weld parameters (voltage, amperage, travel speed, wire feed speed, gas composition) to meet quality and productivity targets.
• Program and optimize other CNC equipment (e.g., laser cutters, turret punches, press brakes, tube benders) using software like SolidWorks, AutoCAD, or nesting programs.
• Develop, evaluate, and improve manufacturing processes for sheet metal fabrication, including laser cutting, punching, bending, forming, welding, and assembly.
• Design and validate tooling, fixtures, and jigs to enhance precision and efficiency in fabrication operations.
• Support New Product Introduction (NPI) by reviewing client designs for manufacturability (DFM), developing weld sequences, tooling requirements, and process documentation.
• Troubleshoot production issues, perform root cause analysis, and implement corrective actions for quality and process problems.
• Troubleshoot robotic weld issues related to fit-up, distortion, porosity, spatter, lack of fusion, etc.
• Analyze production workflows, identify bottlenecks, and implement lean manufacturing principles (e.g., Six Sigma, Kaizen) to reduce waste, improve cycle times, and increase throughput.
• Collaborate with clients, sales, quality assurance, and production teams to ensure projects meet specifications, quality standards (e.g., ISO 9001/AS9100), and delivery schedules.
• Contribute to continuous cost reduction initiatives.
• Ensure compliance with safety regulations, environmental standards, and industry best practices.
• Lead or participate in capital equipment justification, selection, and implementation projects. Interface with integrators and equipment suppliers for installation, startup, and upgrades of robotic weld cells.
• Train production staff on new processes and maintain accurate documentation for repeatability across contract runs.

Qualifications and Requirements

• Associates or Bachelor’s degree in Welding Technology, Manufacturing Engineering, Mechanical Engineering, or related field (or equivalent experience).
• 3–7 years of experience in manufacturing engineering, preferably in sheet metal fabrication or contract manufacturing with an emphasis on programming industrial robots for welding applications.
• Strong knowledge of sheet metal processes (e.g., shearing, laser/plasma cutting, forming, MIG/TIG welding, finishing).
• Proficiency in CAD/CAM software (e.g., SolidWorks, AutoCAD, Nesting software) and ERP/MRP systems.
• Experience with lean manufacturing tools, process optimization, and quality systems (e.g., PFMEA, control plans).
• Excellent problem-solving skills with hands-on experience in root cause analysis and continuous improvement.
• Ability to interpret engineering drawings, GD&T, and weld symbols (AWS standards preferred).
• Ability to support multiple projects and priorities in a fast-paced manufacturing environment.
• Familiarity with industry standards (e.g., AWS welding, ASTM materials) is a plus.

Preferred Skills

• Experience with offline programming software (e.g., RoboGuide, RobotStudio, MotoSim, Delmia).
• Experience with both Fanuc and ABB programming software.
• Knowledge of advanced welding technologies: Vision-guided welding, Laser seam tracking, Through-arc seam tracking (TAST), Adaptive welding system.
• Experience in Lean Six Sigma with a strong problem-solving and continuous improvement mindset.
• Experience in a contract manufacturing or job shop environment with variable production runs.
• Knowledge of automation and robotics in fabrication.
• Understanding of Geometric Dimensioning and Tolerancing (GD&T).
• CAD/CAM experience.