Sr. Robotics Maintenance Engineer

• Design robot trajectories, flow logic, and application parameters for various painting operations (e.g., primer, basecoat, clear coat) using OEM-specific programming languages (e.g., ABB RAPID, FANUC PaintTool, Dürr EcoRPC).

• Utilize advanced simulation tools (e.g., Siemens Process Simulate, Visual Components, or RobCAD) for path generation, cycle time validation, and digital twin modeling.

• Perform paint parameter tuning (e.g., shaping air, atomizing air, fan width, bell speed, fluid delivery rate) to meet transfer efficiency and surface quality targets.

• Lead or support robotic cell integration with conveyors, paint mix rooms, applicators, atomizers, color changers, and environmental control systems.

• Work with OEMs (e.g., Dürr, Eisenmann, ABB, FANUC, Staubli) during design reviews, FAT (Factory Acceptance Test), SAT (Site Acceptance Test), and on-site commissioning.

• Validate robot communication with PLCs, safety systems (e.g., light curtains, emergency stops), and fieldbus protocols (e.g., ProfiNet, Ethernet/IP, DeviceNet).

• Analyze paint application results, including orange peel, DOI, runs, mottling, and overspray, and iteratively refine robot paths and settings.

• Apply knowledge of air flow, booth balancing, and paint chemistry to ensure environmental conditions support defect-free Class A finishes.

• Collaborate with quality engineers to correlate robot performance with surface appearance metrics and participate in defect analysis (e.g., fish eyes, craters, sagging).

• Develop and maintain interlock matrices, robot zone maps, safety-rated speed settings, and teach pendant protocols to meet ISO 10218, ANSI/RIA R15.06, and CE compliance.

• Ensure integration of safety PLCs and emergency response functions with robot controls.

• Manage version control and backups of robot programs, I/O maps, and fault recovery scripts.

• Create and maintain robot recovery procedures and troubleshooting guides for production and maintenance teams.

• Perform downtime analysis related to robotic systems and implement corrective/preventive actions (RCAs, 5 Whys, FMEA).

• Provide support for TPM (Total Productive Maintenance) and predictive diagnostics using condition monitoring tools.

• Serve as the technical lead for paint automation in new model launches, capacity expansions, or system upgrades.

• Coordinate with paint material suppliers, tool vendors, and integrators to align robotic paths with part geometry and coating characteristics.

• Support APQP, PPAP, and SOP milestones by delivering automation deliverables on time and to specification.

• Develop and maintain detailed technical documentation: robots teach routines, process sheets, parameter logs, control architecture, and safety validation protocols.

• Train maintenance technicians and production personnel on robot operation, minor programming changes, and safe handling practices.

• Participate in internal and external audits, providing robot-related process data and conformance reports. 

 • Proficiency in robotic programming environments (RAPID, KRL, PaintPro, VAL3, Teach Pendants).

• Strong understanding of paint shop operations including pretreatment, ED, primer, base coat, clear coat, ovens, and flash-off zones.

• Familiarity with paint delivery systems (e.g., gear pumps, bell atomizers, paint mix rooms, color changers).

• Proficient in reading and developing electrical schematics, robot cell layouts, pneumatic diagrams, and safety zoning plans.

• Strong analytical thinking and a structured approach to problem-solving.

• Excellent written and verbal communication skills.

• Ability to work under pressure in a fast-paced manufacturing environment.

• Proactive team player with a commitment to continuous improvement and innovation.

• Strong leadership, communication, problem-solving, and organizational skills. Ability to work under pressure and lead during emergencies or breakdowns. 

• ABB IRC5 or FANUC Paint Robot certification.

• Six Sigma Green Belt / Lean Manufacturing certified.

• Familiarity with MES integration, traceability systems, and industrial cybersecurity practices.

• Knowledge of ISO 9001, IATF 16949, ISO 14001, and OSHA safety standards.

• Bachelor’s degree in Mechatronics, Robotics, Electrical Engineering, Mechanical Engineering, or Automation Engineering.

• Master’s degree preferred or equivalent professional certifications in robotic automation.

• 5+ years of hands-on experience with industrial robots in an automotive paint shop or OEM/Tier 1 environment.

• Proven track record in commissioning and sustaining high-throughput robotic paint applications.

• Direct experience with leading robot platforms

• Electrical safety certifications and training (NFPA 70E, OSHA standards, etc.) is preferred.