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Direct Job · Hiring
Robot Programmer
📍 Woodruff , SC
KUKA
CLOSED
Details
👥People Needed1
☀️ShiftDays
⏱️Hours/Day10
📅Hours/Week60
Job Description
Per Diem$68.00
Travel Day Per Diem$51.00
Hotel$130.00
Rental Car$60.00
Mileage$0.76
Airfare$800.00
Travel Time$44.00/hr
Travel Conditions
🕒Hours / Round Trip16 hrs
📅Trips / Month1
Q1.Do you have previous experience working in the BMW Woodruff plant and if so please describe in detail.
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
Q1.Are you currently authorized to work in the US?Yes
KUKAMahindra & Mahindra Chakan, India a. Windshield Glass Gluing for SUV Vehicle Robot Used: KUKA KR 120 Application: Dispensing Function: Robot Picks the Glass from Loading Table and Glues the Glass on External Axis and Unloads the Glass on Unloading Table Variants of Glasses: 3 Project Duration: 3 Months b. Carriage Vehicle Glass Gluing Robot Used: KUKA KR 120 Application: Dispensing Function: Robot Picks the Glass from Loading Table and Glues the Glass on External Axis and Unloads the Glass on Unloading Table Variants of Glasses: 2 Project Duration: 2.5 Months c. Truck Vehicles Windshield Glasses Robot Used: KUKA KR120 Application: Dispensing Function: Robot Picks the Glass from Loading Table and Glues the Glass on External Axis and Unloads the Glass on Unloading Table Variants of Glasses: 2 Project Duration: 2 Months Vijay Rolling Mills, India MIG welding Cell with 2 KUKA Robots Robot Used: KUKA KR5 ARC Application: MIG WELDING Function: Robot Welds Child Parts and Marriage Parts on 6 Separate Fixtures placed around 2 Robots. Variants of Parts: 2 Project Duration: 7 Months Ford Motors, Turkey Carriage Vehicle Glass Gluing Robot Used: KUKA KR 120 Application: Dispensing Function: Robot Picks the windshield Glass from Loading Table and Glues the Glass on External Axis and decks it on the Front cabin with the help of Vision Camera and Offsets. Variants of Glasses: 1 Project Duration: 2 Months b. Carriage Vehicle Glass Gluing Robot Used: KUKA KR 120 Application: Dispensing Function: Robot Glues the Glass on the Table. Nozzle with Dispensing Tool is placed on 6th axis of Robot. Variants of Glasses: 14 Project Duration: 4 Months Sandvik Asia, India Machine Tending Robot Used: KUKA KR 120 Application: Machine Tending Function: Robot Moves in Between 3 CNC Machines including Turning Milling and Lathe by Input 100 Kg part from 4 Pallets and Drops them on the Same pallets with help of Parametric Coding. Variants of Parts: 4 Project Duration: 4 Months Pristine Robotics, India MIG Welding Robot Used: KUKA KR5 ARC Application: Aluminum and CO2 welding on Heavy Machinery Parts Function: Robot welds the parts with Fronius Power source working With Weaving Technology for Heavy machined Parts. Variants of Parts: 2 Project Duration: 2 MonthsGood-to-Have
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Q1.Describe in detail your level of experience with AB CompactLogix PLC's.
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
Q1.Are you currently located and authorized to work in the US?Yes
Allen Bradley / Rockwell2002 – Henneke - BMW E53 small parts foaming stations. Complete mechanical, electrical and software design to improve the operation for the loading and unloading of 4 x small part stations for small part foaming on a robot foaming line. This required a new design concept from original design due to unreliability problems. 2003 - Mecanizados - BMW E53 and Saturn LS Vac forming Line Design and build a system that would monitor and control the preheat temperature of vinyl sheeting prior to vac forming (laminating) door panels. The new system used a matrix of temperature sensors on the upper and lower heater banks with the temperature control from Siemens HS724 controllers. The system was controlled from an AB SLC504 PLC and the data was captured to a PC based system running RSView32. Microsoft Excel was used as a way to display the vinyl temperature distribution in reatime mode. 2003 – Frimo - BMW Z4 Foaming Station. Modification to the Z4 foaming station to accommodate BMW E53 foaming tools. This would allow a backup for the E53 foaming process should there be a failure on the E53 foaming line. This required electrical redesign, as well as the writing of extensive software routines, including AB SLC505 PLC and HMI programming. 2004 - 400T Ona Vertical Press (X2) – BMW X5 / X6 door panel lower carrier manufacture. Redesign of safety circuits, including safety gates, safety posts and estop circuits. Redesign of electrical controls, machine interface and PLC software program to improve press cycle and machine reliability. 2008 – BMW E70 /E71 New Glovebox Design. Design and build test station for testing operational integrity of the new glovebox design. The tests included opening time, closing force and interior lamp operation. The installation was built into an X5 body in white, with a permanently mount IP. The glovebox on test was installed in the IP to reproduce the correct environment for testing. The control and operation of the Glovebox was through an AB SLC 504 PLC and data captured was transferred to a PC system and stored. The PC would display in realtime data from each cycle and display it in an Excel spreadsheet as a graph. Tolerances were set to monitor repeatability performance as well deviations. Total cycle count was also monitored. To confirm operation over extended operating cycles. Due to the success of the Glovebox testing the system was upgraded to include opening forces for the sunshade option as well as centre console lid operation. 2010 – Henneke - BMW E70 /E71 & VW411 IP Foaming Line Process. Redesign of the existing BMW E70 / E71 IP foaming line process to integrate it with VW411 foaming line process. This involved the design of the VW411 foaming line process as a stand alone system and then integrating the E70 / E71 IP foaming process into it. This integration involved 2 robots, 2 wet systems and 6 foaming stations. Each foaming station was controlled from a Siemens S7 300 series PLC, as was the VW411 wet system. The BMW E70 / E71 wet system was run from an AB SLC 505 system. Of the 2 robots, one had a single mixhead that was used for the BMW foaming process and the second robot had dual mixhead capability which allowed for the BMW or VW foaming process. It was also necessary to allow, where possible, the ability to run either BMW E70 tooling or VW411 tooling at specific stations. All systems were run on a common Profibus network. A SCADA system was developed to capture all necessary process data from each station for traceability purposes. All process data was displayed on a PC based HMI system running RSView32, allowing BMW & VW data to be available in real time.Good-to-Have
FanucI have experience supporting industrial automation and robotics-related projects involving automated production systems, control integration, PLC communication, and commissioning activities in manufacturing environments. My background combines PLC programming, automation engineering, instrumentation, and industrial process control, which allowed me to work alongside robotic and automated systems used in production operations. I have worked extensively with automation systems integrating: PLC-controlled production equipment Motor control and VSD systems Sensors and industrial instrumentation Automated sequences and interlocks HMI/SCADA monitoring systems Industrial communication networks In manufacturing environments, I supported troubleshooting, commissioning, optimization, and automation improvements for systems operating with robotic and automated machinery. My role included: PLC logic development and modifications Signal validation and I/O testing Fault diagnostics and downtime reduction Equipment startup and commissioning Production automation support Electrical and control system troubleshooting Coordination with operations and maintenance teams I also have strong experience integrating automated equipment with: Siemens PLC systems Allen-Bradley / Rockwell systems HMI and SCADA platforms Ethernet/IP and Profinet communication networks One of my key strengths is quickly understanding automated production processes and supporting reliable machine operation through structured troubleshooting and control system optimization. I have successfully supported commissioning and operational improvements in industrial manufacturing environments where automation reliability and uptime were critical. In addition to technical implementation, I have managed automation project activities including: Functional analysis Technical documentation FAT/SAT execution Site supervision Contractor coordination Client communication and reporting My strong field experience, hands-on troubleshooting ability, and understanding of industrial automation systems enable me to work effectively with robotic production environments and multidisciplinary engineering teams. I am comfortable supporting projects remotely or on-site and can adapt quickly to customer standards, production requirements, and new automation technologies including robotic systems such as FANUC-integrated environments.Good-to-Have
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Automate America, Inc.
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Read the Schedule Before the Rate: What a 60-Hour Week Actually Pays
A KUKA robot programming contract in Woodruff, South Carolina runs 10 hours a day, 6 days a week. That is 60 hours, and 20 of them are overtime — worth about $432 a week on top of the base rate before a single expense is counted. Plus $68/day per diem, $130/day hotel and $800 airfare.
Q1.5-layer system, live in Prod. PlantOS (ERP) sits above MES (OEE), linked by spec. Below MES: SCADA (Eng 1). Below that: Edge HMI — yours. Below that: PLC (Eng 2). Where do you start?
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
Inductive AutomationDeveloped and configured Ignition 8.3 SCADA applications including Gateway architecture, distributed tag providers, and client deployment Configured PLC communications, OPC UA integration, device connections, and real-time tag architecture Developed Perspective and Vision applications including process graphics, alarming, navigation, and equipment visualization Implemented UDTs, parameterized templates, derived tags, and scalable object-oriented SCADA architectures Configured alarm pipelines, historian integration, user roles, and security architecture Developed scripting functionality using Python/Jython for automation, tag interaction, and HMI logic Integrated Ignition platforms with Allen-Bradley, Schneider Electric, Modbus TCP/IP, BACnet, and OPC UA communication networks Performed commissioning, point validation, and live operational troubleshooting for SCADA deploymentsGood-to-Have
College of Engineering, Computing and Applied Sciences
The College of Engineering, Computing and Applied Sciences (CECAS) is committed to producing outstanding graduates, with more than 60 degree and certificate options across all of their campus locations.
CECAS is composed of several schools and departments, with a unique structure of combining engineering and science programs within one college that has led to an uncommon ability to provide a team-based, integrated approach to teaching and research.
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Deshazo Automation
Control Systems
Automation
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📍 Decatur, Alabama
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Free online training for collaborative robot programming. Covers UR robot setup, programming, and safety.
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Industrial Automation & Controls Engineering
📍 Birmingham, MI
Castor Engineering & Consulting
Robot Programming
Contact for pricing
📍 Greater Detroit Area, Michigan
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Direct Job · Hiring
Mechanical Builder
📍 Warsaw, IN
CLOSED
Details
👥People Needed2
☀️ShiftVariable
⏱️Hours/Day10
📅Hours/Week50
Job Description
Per Diem$68.00
Travel Day Per Diem$51.00
Hotel$110.00
Mileage$0.73
Q1.Describe in detail your experience as a Maintenance Technician.
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
Q1.Are you currently authorized to work in the US?Yes
Certificate of Insurance (COI): A current COI must be uploaded to your profile before starting any project. This is essential for compliance with our insurance policy and to protect all parties involved. The minimum coverage required is $1,000,000 in General Liability. If you do not have or wish to obtain the necessary insurance, a deduction of 5% will be included from your billable time each week. Please obtain your COI through the following process if you don't have a current COI already:
Visit Hiscox Insurance.
Enter your Zip Code to specify your state.
Select/Type the nature of your work, for example, "Controls Systems Integration/Automation."
Indicate the structure of your business (Corporation, LLC, etc.). You can select 'Other' if you don't yet have a company started.
Choose the date for your coverage to start.
Ensure you select a minimum of $1,000,000 General Liability Coverage.
Complete the Business Basics fields and follow the prompts to receive your quote.
Remember, quotes from Hiscox are valid for 30 days, and they offer assistance via chat and phone round the clock.
Timesheets and Expense Reports: These must be submitted by 9 AM on Monday mornings. Adherence to this deadline is crucial for maintaining our commitment to clients and for the timely processing of invoices. Please note the following late fee policy:
A late submission beyond the deadline will incur a fee.
Starting from Tuesday, a $100 late fee will be applied.
An additional $50 fee will be charged for each day beyond the initial late period.
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The Six Weeks Nobody Budgets For: Why a New Line Needs a Firefighter Before It Needs a Builder
Commissioning ends, the integrator drives away, and the machine starts telling you everything the runoff never did. Here is why the weeks after handover decide whether a new line hits rate — and why the people who cover them are a different animal from the ones who built it.
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Deshazo Automation
Material Handling
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📍 Decatur, Alabama
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Automation Systems Integration
📍 Troy, MI
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Lear Corporation "” Global automotive technology leader in seating and electrical systems.
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Sure Controls Inc.
Control System Integration - Web Handling
📍 Greenville , WI👥 3 team
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Deshazo Automation
Maintenance
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📍 Decatur, Alabama
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Direct Job · Hiring
Maintenance Technician
📍 Muncie, IN
Allen Bradley / Rockwell
CLOSED
Details
👥People Needed4
🌙ShiftNight Shift
⏱️Hours/Day10
📅Hours/Week70
Job Description
Q1.Describe in detail your experience as a Mechanical or Controls Technician.
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
Q1.Are you currently authorized to work in the US?Yes
Allen Bradley / Rockwell2002 – Henneke - BMW E53 small parts foaming stations. Complete mechanical, electrical and software design to improve the operation for the loading and unloading of 4 x small part stations for small part foaming on a robot foaming line. This required a new design concept from original design due to unreliability problems. 2003 - Mecanizados - BMW E53 and Saturn LS Vac forming Line Design and build a system that would monitor and control the preheat temperature of vinyl sheeting prior to vac forming (laminating) door panels. The new system used a matrix of temperature sensors on the upper and lower heater banks with the temperature control from Siemens HS724 controllers. The system was controlled from an AB SLC504 PLC and the data was captured to a PC based system running RSView32. Microsoft Excel was used as a way to display the vinyl temperature distribution in reatime mode. 2003 – Frimo - BMW Z4 Foaming Station. Modification to the Z4 foaming station to accommodate BMW E53 foaming tools. This would allow a backup for the E53 foaming process should there be a failure on the E53 foaming line. This required electrical redesign, as well as the writing of extensive software routines, including AB SLC505 PLC and HMI programming. 2004 - 400T Ona Vertical Press (X2) – BMW X5 / X6 door panel lower carrier manufacture. Redesign of safety circuits, including safety gates, safety posts and estop circuits. Redesign of electrical controls, machine interface and PLC software program to improve press cycle and machine reliability. 2008 – BMW E70 /E71 New Glovebox Design. Design and build test station for testing operational integrity of the new glovebox design. The tests included opening time, closing force and interior lamp operation. The installation was built into an X5 body in white, with a permanently mount IP. The glovebox on test was installed in the IP to reproduce the correct environment for testing. The control and operation of the Glovebox was through an AB SLC 504 PLC and data captured was transferred to a PC system and stored. The PC would display in realtime data from each cycle and display it in an Excel spreadsheet as a graph. Tolerances were set to monitor repeatability performance as well deviations. Total cycle count was also monitored. To confirm operation over extended operating cycles. Due to the success of the Glovebox testing the system was upgraded to include opening forces for the sunshade option as well as centre console lid operation. 2010 – Henneke - BMW E70 /E71 & VW411 IP Foaming Line Process. Redesign of the existing BMW E70 / E71 IP foaming line process to integrate it with VW411 foaming line process. This involved the design of the VW411 foaming line process as a stand alone system and then integrating the E70 / E71 IP foaming process into it. This integration involved 2 robots, 2 wet systems and 6 foaming stations. Each foaming station was controlled from a Siemens S7 300 series PLC, as was the VW411 wet system. The BMW E70 / E71 wet system was run from an AB SLC 505 system. Of the 2 robots, one had a single mixhead that was used for the BMW foaming process and the second robot had dual mixhead capability which allowed for the BMW or VW foaming process. It was also necessary to allow, where possible, the ability to run either BMW E70 tooling or VW411 tooling at specific stations. All systems were run on a common Profibus network. A SCADA system was developed to capture all necessary process data from each station for traceability purposes. All process data was displayed on a PC based HMI system running RSView32, allowing BMW & VW data to be available in real time.Good-to-Have
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UTI offers hands-on programs in automotive, diesel, welding, HVACR, and more. Programs focus on hands-on, industry-aligned training and in most cases, require less than one year to complete.
Universal Technical Institute is one of the few private career schools in the nation to offer programs that are accredited by the ASE Education Foundation. New campuses opening in San Antonio and Atlanta in 2026.
Sure Controls Inc. "” Automation and controls engineering firm. Providing PLC programming, electrical design, and commis…
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What Automation Work Actually Pays in 2026: 17 Real Contracts, Real Posted Rates
We pulled the published rates off 17 real automation contracts. Controls engineers $56-96/hr. PLC programmers $56-76/hr. Robot programmers $56-68/hr. Per diems from $50 to $200 a day. And the finding almost nobody talks about: 8 of the 17 pay no overtime premium at all.
Tony Wallace·August 12, 2026·5 min read·49 views
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Automate America, Inc.
Automate America connects skilled professionals with companies seeking top talent for automation, controls, and industrial technology contracts across the country.
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Automate America connects skilled professionals with companies seeking top talent for automation, controls, and industrial technology contracts across the country.
Access contracts in automation, controls, and industrial tech
Connect with top companies hiring right now
Build your professional profile and showcase your skills
Q1.Describe your experience with FANUC Robot programming.
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
Q1.Are you currently authorized to work in the US?Yes
FanucI have experience supporting industrial automation and robotics-related projects involving automated production systems, control integration, PLC communication, and commissioning activities in manufacturing environments. My background combines PLC programming, automation engineering, instrumentation, and industrial process control, which allowed me to work alongside robotic and automated systems used in production operations. I have worked extensively with automation systems integrating: PLC-controlled production equipment Motor control and VSD systems Sensors and industrial instrumentation Automated sequences and interlocks HMI/SCADA monitoring systems Industrial communication networks In manufacturing environments, I supported troubleshooting, commissioning, optimization, and automation improvements for systems operating with robotic and automated machinery. My role included: PLC logic development and modifications Signal validation and I/O testing Fault diagnostics and downtime reduction Equipment startup and commissioning Production automation support Electrical and control system troubleshooting Coordination with operations and maintenance teams I also have strong experience integrating automated equipment with: Siemens PLC systems Allen-Bradley / Rockwell systems HMI and SCADA platforms Ethernet/IP and Profinet communication networks One of my key strengths is quickly understanding automated production processes and supporting reliable machine operation through structured troubleshooting and control system optimization. I have successfully supported commissioning and operational improvements in industrial manufacturing environments where automation reliability and uptime were critical. In addition to technical implementation, I have managed automation project activities including: Functional analysis Technical documentation FAT/SAT execution Site supervision Contractor coordination Client communication and reporting My strong field experience, hands-on troubleshooting ability, and understanding of industrial automation systems enable me to work effectively with robotic production environments and multidisciplinary engineering teams. I am comfortable supporting projects remotely or on-site and can adapt quickly to customer standards, production requirements, and new automation technologies including robotic systems such as FANUC-integrated environments.Good-to-Have
Rockwell Automation Academy of Advanced Manufacturing
The Logix, Drives, and Motion Certificate Programs are intended for maintenance and programming professionals who want to develop their knowledge and skills using the latest technology.
Rockwell Automation offers self-paced e-learning, virtual instructor-led training, and hands-on laboratory experience in automation technology courses covering control, visualization, drives, motion, and more.
Automate America connects skilled professionals with companies seeking top talent for automation, controls, and industrial technology contracts across the country.
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Q1.Describe in detail your experience as a Maintenance Technician.
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
Q1.Are you currently authorized to work in the US?Yes
Certificate of Insurance (COI): A current COI must be uploaded to your profile before starting any project. This is essential for compliance with our insurance policy and to protect all parties involved. The minimum coverage required is $1,000,000 in General Liability. If you do not have or wish to obtain the necessary insurance, a deduction of 5% will be included from your billable time each week. Please obtain your COI through the following process if you don't have a current COI already:
Visit Hiscox Insurance.
Enter your Zip Code to specify your state.
Select/Type the nature of your work, for example, "Controls Systems Integration/Automation."
Indicate the structure of your business (Corporation, LLC, etc.). You can select 'Other' if you don't yet have a company started.
Choose the date for your coverage to start.
Ensure you select a minimum of $1,000,000 General Liability Coverage.
Complete the Business Basics fields and follow the prompts to receive your quote.
Remember, quotes from Hiscox are valid for 30 days, and they offer assistance via chat and phone round the clock.
Timesheets and Expense Reports: These must be submitted by 9 AM on Monday mornings. Adherence to this deadline is crucial for maintaining our commitment to clients and for the timely processing of invoices. Please note the following late fee policy:
A late submission beyond the deadline will incur a fee.
Starting from Tuesday, a $100 late fee will be applied.
An additional $50 fee will be charged for each day beyond the initial late period.
Automate America connects skilled professionals with companies seeking top talent for automation, controls, and industrial technology contracts across the country.
Access contracts in automation, controls, and industrial tech
Connect with top companies hiring right now
Build your professional profile and showcase your skills
Requirements that applicants must meet to be eligible
Yes = Able to Apply, No = Not Able to Apply
US Work Authorization RequiredRequired
SiemensActivities at Ford Sharonville Transmission Plant - USA: ◼ I created new PLC logic and modified the PLC HMI screen to reduce the processing time of rejected parts by adding new data exchange that stores and displays the reason for each rejected part directly on the PLC HMI. This improvement eliminated the need to manually write down the serial number of every rejected part and then access the Gauge HMI application to obtain the gauge report and identify the rejection reason for each listed serial number. To implement this enhancement, I coordinated with the Gauge personnel to include the status of the tested features in the data exchange, ensuring that all relevant inspection information was available immediately on the PLC HMI. Commissioning the 8F57 PCA Expansion line: o Implementing PLC program improvements and providing customer support until production startup, including adding new PLC logic to solve conveyor issues (parts crashing, releasing parts) and fixing issues with the communication with Gleason stations (OD and RD load Gear), solving the OP250 (Rollscan devices) issues. o Identify the root cause of broken grippers at OP040 and OP045 (Load OD & RD gears on the carrier) reviewing and adjusting the settings of the XRef drive reducing rejected parts in addition to avoid damaging the slide gripper fingers at OP40 & OP45). ▪ Commissioning Palletized Conveyor/line: o Making PLC program improvements and providing customer support until production startup, including adding new PLC logic to solve the RFID issue (biggest problem of the whole line), the Master-Slave Keyence cameras issues and adding new data to get, display and exchange the reason of a part rejected of the “Intra” gauge. o Reviewing and finding the solution to fix the communication issue between the PLC and the IT Server (CPN Switch/HUB problem). o Identifying and solving the cause why the line was not running (Laser Station not running – Servo issue). • Commissioning Contour/Broach/B1034 South line: o Implementing PLC program improvements and providing customer support until production startup. Including adding new PLC logic to fix the Master-Slave Keyence cameras, fixing the change model issues and adjusting PLC logic and setting all the sensors after the Hardness machine. • Support MCA BORE BUILD line: o Identify and solve the FIS communication problem (data exchange) of all the stations on both conveyors (IVB & OVB) as well as extracting and sharing with IT, the descriptions of the fault messages. Activities at Gilman-ES site – Janesville, WI - USA: • Commissioning Battery Cell (TIM, Foam & Epoxy) for Ford CA (Ford Research and innovation center) – Ongoing project. • Support debugging the Washer Load Machine (AP09_0200_0280_Batwings - Ford Livonia) in addition to supporting the machine runoff (by Ford personnel). Activities at ABB USA site – Auburn Hills, MI. - Ford Irapuato machines: • Support running, debugging and solving some issues at OP010.1 MOD-2, OP10.1 MOD3, OP010.2 MOD-2, OP020.2 MOD-2, and OP030.1 MOD-3. • Install PLC program, configure hardware and start running dry cycle of OP010.1 MOD1. • Support debugging OPGE2 Gear Set Assy Line (Vandyke – OP100 & OP110). Activities at Ford Vandyke Plant - USA: • Support debugging OP020.2 MOD3. • Provide production support in the absence of the assigned Controls Engineer. Activities at Ford Irapuato Plant - México: ◼ Support customer in identifying the causes of slow cycle time. After commissioning the OP OP030.1 station, achieving the cycle time requested by the customer, and obtaining early validation (it was the first machine approved in this project) I assisted in identifying and reporting the reason behind the fluctuation of JPHs. The machine cycle was being interrupted frequently due to several factors related to material quality and human resources: ▪ Low- quality subcomponents. Significant time was wasted producing rejected parts and restating production after a bad cycle. The customer eventually assigned personnel from the Materials department and managed this issue, but this was the main problem for some days before Ford took corrective action. ▪ Robot core-release optimization. I proposed changing the way the Robot released the cores in the press station: releasing them as soon as the core aligned with the Shaft (letting gravity complete the final positioning) instead of waiting for the end of the Robot's slow downward movement. This modification was implemented, tested, and approved. ▪ Insufficient personnel at OP030.1 . This machine is very fast, and the assigned operators were constantly rushing. Their responsibilities included loading finished parts, visually inspecting parts, taking measurements and recording them, unloading finished parts, packing, removing rejected parts from the ED40 press, restarting the auto cycle after interruptions removing empty carts, bringing new/full carts from OP020's, and more. ▪ Waiting time for material/subcomponents. I observed frequent shortages of shafts and, at other times, a lack of cats with core stacks ready for OP030.1. ▪ Delayed operator response to empty carts. Sometimes operators did not immediately notice that a cart was empty, causing the continuous cycle to pause while waiting for new core stacks (take out the empty cart, bring/insert a new one). ▪ Blocked unload conveyor. There were short but frequent pauses when the Robot could not unload finished parts because the unload conveyor had no empty pallets available. ▪ Balancer faults. Occasionally, the balancer machine generated faults requiring Ford personnel to manually remove the part, adjust clamps or sensors, and restart the station. This required powering off the equipment and opening the safety door, increasing downtime. ▪ Extended balancing time . In some cases, balancing a part took longer than expected. Support from the Balancer OEM could help, since the OP030.1 cycle time includes the Balancer cycle time. ▪ Data loss in the Balancer Equipment , after part rejection. When the Balancer equipment rejected a part, the operator had to manually remove it. Sometimes the Balancer lost its data for no clear reason, increasing downtime because the operator had to turn off the machine, enter the station, remove the part from the Balancer, and restart the equipment. • Commissioning OP030.1 MOD1 (e-Rotor line), implementing PLC program improvements, providing customer support until full production started. This equipment was the first one to be fully validated by the customer. • Support debugging & solving Promess Press and communication issues at OP020.1 (EtherCAT, zero pos.). • Support debugging and solving OP020 missing data at OP030.1. Activities at Ford Chihuahua Engine Plant - México - Dragon Project – OP170.1A: • Support Installing new Hardware (Scanner DMR-370, etc.) • Debug and solve several OP0170 issues (keys feeder, blowing conditions, key level at Magazine, etc). • Improve OP170 Cycle time (31 sec. to 25 sec.). • Fixing data exchange communication issues (PLC Logic - IT/FIS) at OP170.1A (Aux. waiting, etc.). • Fixing FIS comm. error of OP's 160 (1Fdr, 4D & 2Fdr), OP170 (1CN1, 1Fdr, 2Fdr & 2Fdr), OP220.1 & OP220.3. • Fixing Main Conveyor (S3) blocked (extra part released from decision point of OP220.1 to OP220.3. Activities at Ford Lima Engine Plan t - USA: • Install the new Fasttrack System (Conveyor) into the current conveyor (FCHA area). The installation (new hardware, update PLC program, start up, debugging, etc.) was done and validated one week earlier/faster than planned since there were no issues with the programming nor the hardware thanks to the work done offline at ABB site. • Production Support. Activities at Ford Dearborn Engine Plant - USA: • Close open/pending issues. • Washer machines issues at Block line (MB220_1, MB220_2) and Head line (MH220_1, MH220_2). • Servo Drive issue at OP0070. • Fixing FIS PLC logic of all stations in the washer machines (4). • Update HMI Screen at MB220_2. Activities at Ford Sterling Axle Plant - USA: • Close open/pending issues. • Washer machine issues (D23 – OP020 & OP040). • Onsite Support – D73 Welder (Motor replacement at OP100, Grippers replacement at 0P060, Loctite and Vision System support at OP030, Reject Station support – OP055).Good-to-Have
Our History: 25 Years in Automation, From a Stamping Die to a Marketplace
Automate America was founded in 2001 as a DBA, incorporated as Wallace Automation on 23 August 2004, and opened as a public marketplace on 17 November 2018. In between: body-shop robots at Ford and Chrysler, 52 people at peak, over 30 programmers at BMW Spartanburg, our own vision systems, and projects in Shanghai, England and South Africa. The whole timeline, first-hand.
Cuyahoga Community College (Tri-C) is Northeast Ohio's largest community college, operating one of the country's largest manufacturing technology trai...
Industrial WeldingIntegrated Systems Engineering TechnologyManufacturing TechnologyCNC Machining
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At Michigan Engineering, we educate, innovate, and lead by fostering interdisciplinary collaboration, advancing knowledge, and preparing engineers to solve society's greatest challenges.
Our vision is: Educating visionary leaders and advancing bold discoveries to shape a better world. With 13 top-ranked departments and $369M in research expenditures.
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Lincoln Tech: Training Tomorrow's Skilled Workforce
Lincoln Tech offers career-oriented programs in five principal areas: automotive technology, health sciences, skilled trades, business and information technology, and hospitality services.
More than 426,000 job openings projected nationwide for Welders between 2022 & 2032. Our 88,000 square foot campuses offer automotive, welding, electrical and HVAC training to meet this demand.
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Automate America connects skilled professionals with companies seeking top talent for automation, controls, and industrial technology contracts across the country.
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Siemens Xcelerator Academy offers certification exams for those who have completed training or have experience with their products. Manufacturing courses help prepare students to obtain Siemens PLC and Solid Edge certifications.
Comprehensive online PLC training tailored for engineers, technicians, and automation enthusiasts, providing in-depth training on Siemens PLC programming using the TIA Portal software for S7-1200, S7-1500, S7-300, and S7-400 platforms.
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Automate America connects skilled professionals with companies seeking top talent for automation, controls, and industrial technology contracts across the country.
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Automate America connects skilled professionals with companies seeking top talent for automation, controls, and industrial technology contracts across the country.
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