Role summary
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.
Responsibilities
- Supervise and lead a team of electrical maintenance technicians assigned to the paint shop robotics activities as fellows
- Design robot trajectories, flow logic, and application parameters for various painting operations using OEM-specific programming languages
- Utilize advanced simulation tools for path generation, cycle time validation, and digital twin modeling
- Perform paint parameter tuning such as shaping air, atomizing air, fan width, bell speed, and 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 during design reviews, Factory Acceptance Test, Site Acceptance Test, and on-site commissioning
- Validate robot communication with PLCs, safety systems including light curtains and emergency stops, and fieldbus protocols
- 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
- 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 and preventive actions
- Provide support for 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 including robot 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
- Proficiency in robotic programming environments