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Advanced Controls and Robotics Technician - Welding Cells
Advanced Controls and Robotics Technician - Welding CellsChallenge Manufacturing Company • Grand Rapids, MI, US
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Advanced Controls and Robotics Technician - Welding Cells

Advanced Controls and Robotics Technician - Welding Cells

Challenge Manufacturing Company • Grand Rapids, MI, US
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Job Description

Job Description

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.
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