Manufacturing Engineer (Robotic Weld)

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 Solid Works, 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., Solid Works, 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., Robo Guide, Robot Studio, Moto Sim, 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 Familiarity with welding codes and standards (AWS D1.1, ISO standards, etc.) Ability to simulate weld paths, reach, and cycle times virtually. 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. An understanding of Geometric Dimensioning and Tolerancing (GD&T). CAD/CAM experience.