Experienced ABB Robot Programmer - Welding & Plasma Cutting Automation

Ken Garner Manufacturing • Chattanooga, TN

2d • Onsite

About The Position

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.

Requirements

• 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

Nice To Haves

• 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

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, track systems, 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

Benefits

• Employees are eligible for a full benefit package: 10 paid holidays + 1 week vacation after 6 months, 2 weeks after 18 months, 3 weeks after 5 years, 4 weeks after 10.
• Medical, dental and vision insurance is offered at very reasonable rates.
• Family coverage is approximately $100 per week.
• Company paid life insurance for employee, optional coverage is available for family at additional discounted cost.
• Uniforms provided.
• Pay is weekly.
• Regularly scheduled performance reviews.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Education Level: Associate degree