What are the responsibilities and job description for the JobExperienced ABB Robot Programmer - Welding & Plasma Cutting Automation Title position at Ken Garner Manufacturing Co?
We are seeking an experienced ABB Robot Programmer with hands-on expertise in IRC5 controllers and welding automation. The ideal candidate will be responsible for programming, optimizing, maintaining, and servicing ABB robotic systems within our production environment. This is a critical role that requires both deep technical programming knowledge and a strong understanding of welding processes.
KEY RESPONSIBILITIES
Programming & Offline Simulation
- Write, edit, and troubleshoot ABB RAPID language programs from scratch for welding and plasma cutting applications
- Develop and simulate robot programs using ABB RobotStudio offline programming software
- Build and maintain virtual cell models and deploy validated programs to the production floor to minimize rework
- Configure tool and work object calibrations, coordinate systems, and TCP setups
IRC5 Controller Operations
- Operate and program ABB IRC5 controllers using the FlexPendant teach pendant
- Configure I/O systems, safety panels, and MultiMove functionality for coordinated multi-robot cells
- Read and resolve IRC5 error and event logs; troubleshoot faults including motor calibration errors, SMB battery issues, and axis limit faults
Welding & Plasma Process Expertise
- Configure ABB Weld Guide arc welding packages and set up MIG weld data records within RAPID programs
- Dial in MIG welding parameters including wire feed rate, voltage, amperage, travel speed, shielding gas flow, and weave patterns based on material type and thickness
- Optimize plasma cut speeds, torch height control, kerf width, pierce delays, and cut path sequences through robot programming
- Ensure MIG weld quality compliance with applicable standards (e.g., AWS D1.1) and plasma cut dimensional tolerances
Servicing & Preventive Maintenance
- Perform scheduled preventive maintenance per ABB product manual intervals, including axis gearbox lubrication, SMB and controller battery replacement, and cable harness inspection
- Service IRC5 cabinet components including drive unit inspection, fan replacement, and DSQC board identification and swapping
- Maintain MIG welding torches, wire feeders, liners, contact tips, and diffusers, as well as plasma torch consumables including nozzles, electrodes, and shields
- Service external positioners and other peripherals integrated into the robot cell
- Maintain accurate service logs, track consumable replacement cycles, and perform root cause analysis on recurring faults to maximize system uptime
Safety
- Enforce lockout/tagout (LOTO) procedures and robot safety cell protocols at all times
- Conduct safety audits of robot cell perimeters, light curtains, and interlocks
REQUIRED QUALIFICATIONS
- 3–5 years of hands-on ABB robot programming experience in a manufacturing environment
- Proficiency in ABB RAPID programming language
- Direct, demonstrable experience with IRC5 controllers and the FlexPendant
- Experience with ABB RobotStudio offline programming and simulation
- Strong understanding of MIG/MAG welding processes and desirably plasma cutting operations as well.
- Ability to read and interpret mechanical drawings, weld symbols, and electrical schematics
- Solid troubleshooting skills for both programming and mechanical/electrical faults
PREFERRED QUALIFICATIONS
- ABB Robotics certification or formal ABB training coursework
- AWS welding certification or equivalent welding knowledge credential
- Experience with ABB SafeMove safety configuration
- Familiarity with MultiMove coordinated robot cell programming
- Experience integrating ABB robots with PLCs and external vision or seam tracking systems
- Associate’s or vocational degree in Robotics, Automation, Welding Technology, or a related field
- Experience with plasma cutting processes
WORK ENVIRONMENT This position requires working in an active manufacturing environment that includes exposure to welding fumes, plasma cutting operations, heat, noise, and industrial equipment. Appropriate PPE is required and provided. Candidates must be able to lift up to 50 lbs and work in a standing or kneeling position for extended periods.