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KUKA Robot Programmer / Automation Technician

JOB SUMMARY

The KUKA Robot Programmer / Automation Technician is responsible for supporting and maintaining automated robotic welding systems within a high-volume manufacturing environment. This role focuses on robot troubleshooting, production support, program modifications, weld process optimization, and minimizing equipment downtime. The technician will work with robotic welding cells, automated fixtures, PLC-controlled systems, and related automation equipment to ensure safe and efficient production operations.

RESPONSIBILITIES

• Provide production support for automated robotic welding cells and robotic manufacturing systems
• Troubleshoot and recover KUKA robots from faults, alarms, crashes, and production interruptions while restoring systems to operational status quickly and safely
• Modify, optimize, and troubleshoot KUKA robot programs for welding and material handling applications
• Perform robot touch-ups, TCP verification, path corrections, and position adjustments
• Support robotic applications including MIG welding, resistance welding, projection welding, and pneumatic systems
• Diagnose and repair electrical, mechanical, pneumatic, hydraulic, and robotic system issues
• Troubleshoot automated welding cells to identify root causes and implement corrective actions that reduce downtime and improve reliability
• Read and interpret electrical schematics, blueprints, weld prints, and technical documentation
• Troubleshoot and repair:
  • Servo drive systems
  • Motors and encoders
  • Relays and control boards
  • Sensors and safety devices
  • Wiring harnesses and electrical panels
• Perform minor fixture adjustments, shim modifications, and weld tooling corrections based on manufacturing requirements
• Support and maintain communication networks including Ethernet, Remote I/O, and DeviceNet systems
• Perform basic offline programming and simulation using KUKA programming software and robotic simulation tools (KUKA.Sim)
• Support integration and troubleshooting of PLC-controlled automation systems
• Assist with robotic startup activities, program validation, and production launches
• Ensure compliance with all customer, plant, and safety procedures while working around robotic and automated equipment
• Maintain detailed documentation of repairs, troubleshooting activities, and process improvements
• Communicate equipment concerns, downtime issues, and shift updates effectively with supervisors and team members
• Work independently with minimal supervision while supporting production requirements

REQUIRED SKILLS & QUALIFICATIONS

• Experience troubleshooting and programming KUKA robotic systems in an industrial manufacturing environment
• Strong understanding of robotic welding processes and welding fundamentals
• Knowledge of:
  • KUKA KRC4 / KRC5 controller systems
  • KUKA Robot Language (KRL) programming
  • Robotics and automation systems
  • Electrical circuitry and controls
  • Pneumatics and hydraulics
  • Industrial mechanics
  • Servo systems and automation components
• Ability to troubleshoot electrical systems using schematics and prints
• Experience with:
  • TCP setup and verification
  • I/O troubleshooting and simulation
  • Program touch-ups and path modifications
  • Weld process troubleshooting
  • Robot recovery procedures
• Understanding of automated weld fixtures and shimming processes
• Familiarity with PLC-controlled manufacturing equipment
• Proficient with Microsoft Office applications including Word, Excel, and Outlook
• Strong communication and problem-solving skills
• Ability to prioritize tasks and respond effectively in a fast-paced production environment

PREFERRED QUALIFICATIONS

• Industrial Maintenance, Electrician Journeyman, Mechatronics, or Machine Repair certification
• Associate degree in Mechatronics, Robotics, Automation, Electrical Technology, or related field
• Previous experience supporting KUKA robotic welding systems in automotive or automated manufacturing environments
• Experience with KUKA.Sim or other offline robotic programming and simulation software
• Strong electrical and mechanical troubleshooting background

WORK ENVIRONMENT / PHYSICAL DEMANDS

• Frequent exposure to noise, sparks, smoke, heat, dirt, grease, oil, and welding fumes
• Regularly works around automated robotic equipment and high-speed production machinery
• Exposure to high and low voltage electrical systems
• Frequent walking, bending, twisting, lifting, and entering robotic weld cells
• Required use of PPE including eye protection, hearing protection, gloves, and cut-resistant equipment
• Potential exposure to Arc Flash hazards while working in electrical cabinets and control panels

BEHAVIORAL EXPECTATIONS

• Demonstrates accountability, reliability, and strong attention to detail
• Maintains a high sense of urgency while supporting production needs
• Works effectively both independently and within a team environment
• Communicates professionally with supervisors, maintenance personnel, and production teams
• Adapts positively to changing production priorities and plant requirements
• Maintains strong attendance and dependability
• Focuses on continuous improvement, safety, and equipment reliability

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