Senior Desiign Automation Engineer

Job Title

Automation Design Engineer

– Automotive Welding

Job Summary

You will design, develop, and test automated welding systems and robotic tooling for automotive manufacturing. Your work includes creating 3D models, selecting automation equipment, and ensuring designs meet safety and customer standards.

Key Responsibilities

• Design Systems: Create 3D models and 2D manufacturing drawings for robotic welding cells, end-of-arm tooling, and assembly fixtures using CAD software like SolidWorks or AutoCAD.
• Integrate Robotics: Select and integrate industrial robots, welding guns (MIG, TIG, Resistance/Spot), sensors, and safety hardware.
• Collaborate: Work with project managers, controls engineers, and the shop floor to ensure designs are practical and buildable.
• Review Safety: Ensure all mechanical and automation designs follow OSHA, RIA, and customer-specific safety standards.
• Support Build & Launch: Assist with assembly troubleshooting, robot path simulations, and final buy-off at customer sites if needed.

Qualifications & Skills

• Education: Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or a related field (or equivalent practical experience).
• Experience: 3 to 5 years of experience in automation design, specifically within the automotive or tier-1 welding supplier industry.
• Software Skills: Proficiency in 3D CAD software (SolidWorks, CATIA, or Inventor) and robotic simulation tools (Robcad or Process Simulate).
• Knowledge Base: Strong understanding of resistance spot welding, MIG welding, pneumatic components, and geometric dimensioning and tolerancing (GD&T).

Job Title: Process Automation Design Engineer

– Automotive Welding Systems

Department: Process Engineering / Automation

Reports To: Engineering Manager

Position Summary:

The Process Automation Design Engineer is responsible for designing, simulating, and optimizing complete automated welding manufacturing lines. This role focuses on the macro-level process layout, material flow, cycle-time (thru-put) analysis, and the high-level integration of FANUC robotic arms into coherent production cells.

Key Responsibilities:

• Process & Layout Design: Develop 2D/3D manufacturing line layouts, sequence of operations, and process flow diagrams for robotic MIG, spot, and laser welding cells.

• FANUC Robot Simulation: Utilize simulation software (such as FANUC ROBOGUIDE or Process Simulate) to perform reach studies, interference checks, and cycle time analysis.

• System Integration: Define the interaction between FANUC robots, material handling systems, safety gating, and PLC-controlled equipment.

• Cycle Time Optimization: Analyze and optimize robot paths and process steps to meet strict automotive customer throughput requirements.

• Specifications & Standards: Ensure all process designs comply with automotive OEM specifications (e.g., Ford, GM, Stellantis) and safety standards (RIA/OSHA).

• Cross-Functional Collaboration: Partner with Tooling Design Engineers to align fixture placement with robot access paths and process constraints.

Qualifications:

• Education: Bachelor’s degree in Mechanical, Manufacturing, or Automation Engineering.

• Experience: 3+ years in automotive process automation design, focusing on robotic welding lines.

• Technical Skills: High proficiency in FANUC ROBOGUIDE, AutoCAD, and 3D CAD platforms. Deep knowledge of MIG/MAG and resistance spot welding parameters.

• Knowledge: Strong understanding of automotive assembly line routing, safety circuits, and line balancing.

Job Title: Tooling Automation Design Engineer

– Welding & FANUC

Department: Mechanical Design / Tooling

Reports To: Tooling Engineering Supervisor

Position Summary:

The Tooling Automation Design Engineer is responsible for the mechanical design of welding fixtures, clamping systems, and specialized End-of-Arm Tooling (EOAT) for FANUC robots. This role ensures parts are held precisely to meet tight tolerances during high-stress robotic welding applications.

Key Responsibilities:

• Fixture & Tooling Design: Design 3D geometric welding fixtures, manual/pneumatic clamping systems, and heavy-duty robotic EOAT using SolidWorks, CATIA, or NX.

• FANUC Payload & Center of Gravity (CG) Analysis: Calculate load capacities, moments of inertia, and CG for EOAT to ensure compliance with specific FANUC robot payload profiles.

• Component Selection: Specify standard automation components including pneumatic cylinders, toggle clamps, proximity sensors, grippers, and slide units.

• GD&T Application: Apply strict Geometric Dimensioning and Tolerancing (GD&T) to fabrication prints to ensure part repeatability and quality.

• Welding Environment Design: Material selection and shielding design to withstand weld spatter, high heat, and harsh production environments.

• Build Support: Support the toolroom build, assembly, shim-tuning, and try-out phases of fixtures and EOAT.

Qualifications:

• Education: Bachelor’s degree in Mechanical Engineering, Tool & Die Design, or equivalent trade experience.

• Experience: 3+ years designing physical tooling, fixtures, and robotic grippers for automotive body-in-white (BIW) welding applications.

• Technical Skills: Advanced 3D CAD modeling skills (SolidWorks preferred); strong knowledge of pneumatics and fluid power schematics.

• Knowledge: Deep understanding of FANUC robot mechanical mounting interfaces and payload constraints.