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Senior Robotic Welding Automation Technician
Senior Robotic Welding Automation TechnicianChallenge Manufacturing Company • Walker, MI, US
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Senior Robotic Welding Automation Technician

Senior Robotic Welding Automation Technician

Challenge Manufacturing Company • Walker, MI, US
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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.
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    Automation Technician • Walker, MI, US

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