Robotic Welder & Programmer

Summary

The Robotic Welder & Programmer sets up, programs, operates, and maintains robotic welding cells and also performs hands-on manual welding and fabrication on the shop floor. This position develops and refines weld programs, dials in fixtures and weld parameters, and runs production parts, while welding manually on work that is not suited to automation. Performs process evaluation, develops process work instructions, balances work flow, and helps design product build fixtures with the goal of improving quality, reducing costs, and increasing throughput.

Essential Duties and Responsibilities

Employee must be able to perform these essential functions of the position satisfactorily and, if requested, reasonable accommodations may be made to enable employees with disabilities to perform the essential functions of the job, absent undue hardship.

• Sets up, programs, and troubleshoots robotic welding cells using the teach pendant and/or offline programming software; creates, edits, and optimizes weld paths, sequences, and parameters (voltage, wire feed speed, travel speed, and weave). Subject Matter Expert for Robotic Welding operations.
• Performs hands-on manual welding and fabrication on the shop floor - MIG (GMAW), on parts not suited to the robot and to support production demand.
• Loads programs, dials in fixtures and part positioning, and runs first-article and production parts to confirm weld quality before and during a run.
• Reads and interprets blueprints, weld symbols, and work instructions; fits, tacks, and assembles weldments to specification.
• Diagnoses and corrects cell issues such as torch collisions, wire-feed faults, arc-start problems, and positioner or I/O errors; performs routine preventive maintenance, TCP calibration, and consumable changeover on robots and welding equipment.
• Grinds, finishes, and prepares parts to meet quality and cosmetic requirements.
• Develops and documents process work instructions, balances work flow, and designs or recommends product build fixtures to improve quality, cost, and throughput.
• Performs in-process inspection and verifies welds against applicable standards (e.g., AWS D1.1); maintains accurate setup and production records.
• Actively participates in the Company Safety Program with goal of ensuring a safe and suitable work environment for all employees and meeting the requirements mandated by the Occupational Safety and Health Standards.
• Applies lean tools and methods and participates in continuous improvement activities.
• Provides assistance to other departments, as needed.
• Performs all other duties as assigned.
• Complies with the requirements of the company's ISO 9001 Quality Management System (when required).

Physical Requirements

• Ability to stand, climb, bend and kneel on a regular basis.
• Prolonged periods of standing while welding, fitting, and operating equipment, with periodic work at a computer or teach pendant.
• Regular manual dexterity/coordination: hand/eye movements, motor control.
• Regular visual effort: concentrated reading of documentation or close viewing of computer displays.
• Will routinely work in factory environment with exposure to noise and machinery.
• Able to push, pull and lift up to 50lbs. on a regular basis.
• Able to push, pull and lift up to 75lbs. on an occasional basis.

Potential Hazards

• Employee may be exposed to hazardous substances including a variety of petroleum-based products, cleaning solvents, and welding fumes and gases on a regular basis.

• Employee may be exposed to sharp (cutting) tools, hot metal, sparks, arc flash / UV light, and high noise on a regular basis; appropriate PPE is required.

Competencies necessary to perform this job

• Time Management - Effective time management skills to independently complete tasks with minimal disruption to company users.
• Organization - Ability to prioritize multiple tasks and maintain a smooth work flow.
• Teamwork - Ability to work closely with a variety of employees while maintaining a positive attitude.
• Problem Solving - Identify and resolve problems in a timely manner.
• Communication - Speak clearly and persuasively in positive or negative situations. Ability to ask detailed questions to comprehend requests.
• Safety and Security - Follow safety policies/plans created by the company; utilize tools and equipment in a safe and proper manner.

Required Education/Experience/Skills

• High school diploma or equivalent; completion of a welding or robotics/automation program, or significant related experience in a metal fabrication and welding environment.
• Minimum of 2 years of production (on-the-floor) welding experience in MIG (GMAW), with the ability to read blueprints and weld symbols.
• Minimum of 2 to 3 years of hands-on robotic welding programming experience (e.g., FANUC, Yaskawa/Moto man, Lincoln, or Miller/Panasonic systems), including teach-pendant programming.
• Skilled in the use of Microsoft Office products and other data systems to include Global Shop.
• Ability to meet deadlines; to understand and follow written and verbal instructions.
• Ability to understand and follow posted work rules and procedures.
• Ability to prioritize, organize, solve problems, and complete tasks independently.
• Mechanical aptitude with strong attention to detail and weld quality.
• Ability to communicate effectively and work cooperatively with members of management, vendors, and other employees.

Preferred Education/Experience/Skills

• Knowledge of Quality Systems, Lean Manufacturing techniques, weld fixture design, and offline robotic programming or simulation (e.g., FANUC ROBOGUIDE, Robotmaster).
• Familiarity with GD&T and in-process weld inspection.

Certifications, Licensees or Registrations Required/Preferred

• AWS welding certification(s) preferred. Manufacturer robotic programming / operation training preferred but not required.