Sr. Robotics Maintenance Engineer

Position Overview:
The Sr. Robotics Engineer plays a pivotal role in the design, development, integration, and lifecycle support of advanced robotic systems in high-throughput automotive paint operations. This position is responsible for programming and commissioning robotic painting and sealing equipment, ensuring precise application of coatings, and aligning automation capabilities with production and quality targets. The role requires collaboration with cross-functional teams including process engineering, controls, facilities, quality, and production to ensure best-in-class paint application, high reliability, and compliance with OEM and regulatory standards.

Key Responsibilities:
Supervise and lead a team of electrical maintenance technicians assigned to the paint shop robotics activities as fellows

Robotic System Design and Programming

• 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.

Equipment Integration & Commissioning

• 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).

Process Optimization & Quality Assurance

• 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).

Control, Safety, and Compliance

• 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.

Support and Maintenance

• 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.

Cross-functional Project Management

• 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.

Documentation & Training

• 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.

Skills Technical Skills:

• 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.

Soft Skills:

• 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.

Preferred Certifications and Skills:

• 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.

Soft Skills:

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

Minimum Qualifications:

• 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.