Thomas — Robotics Engineer

I am an advanced FANUC Robot Programmer and Controls Startup Specialist with extensive hands-on experience commissioning, programming, integrating, and troubleshooting robotic automation systems in high-volume automotive manufacturing environments. My experience extends well beyond teaching points or creating simple robot programs—I specialize in bringing complete robotic cells from installation through production while minimizing downtime and resolving complex automation issues.

I have experience programming FANUC collaborative robots, including the CRX-25iA and CRX-35iA platforms, as well as traditional industrial FANUC robots using R-30iB controllers. I am proficient in TP programming and routinely develop structured, modular programs utilizing motion instructions (Joint, Linear, and Circular), Position Registers, Numeric Registers, Digital Inputs and Outputs, Group Inputs and Outputs, Flags, Timers, Wait conditions, IF statements, Labels, JMP instructions, CALL programs, conditional logic, and production sequencing.

I have a strong understanding of robot fundamentals, including User Frames, Tool Frames, TCP calibration, payload configuration, mastering, coordinate systems, recovery procedures, motion optimization, singularity avoidance, collision prevention, and safe production operation. I design robot programs with reliability, maintainability, and production efficiency in mind rather than simply achieving robot movement.

One of my strongest technical areas is FANUC vision integration. I have worked extensively with FANUC iRVision and 3DV vision systems, developing and troubleshooting vision-guided applications that perform part location, offset compensation, coordinate transformations, and robotic pick-and-place operations. I understand how vision data interacts with User Frames, Tool Frames, Position Registers, and motion instructions, allowing me to diagnose complex issues that are often overlooked. For example, while commissioning a gantry robot for an automotive Y-pipe application, I identified that Z-axis positioning errors were caused by duplicate offset calculations from both the stacking routine and the 3DV vision system. By eliminating the redundant offset, I restored accurate picking without requiring recalibration or hardware replacement.

My experience also includes extensive robot-to-PLC integration. I routinely work with EtherNet/IP communications and understand production handshake logic, including Robot Ready, Cycle Start, Busy, Complete, Fault Reset, Part Present, and Auto Mode signals. I am comfortable configuring and troubleshooting communications between FANUC robots, PLCs, HMIs, RFID systems, sensors, and other automation devices.

I approach troubleshooting from a systems perspective rather than assuming the robot is always the source of the problem. During a production shutdown at an automotive battery assembly facility, I was able to determine that the robot was functioning correctly and quickly traced the fault to a failed RFID communication device within the PLC system. After restoring communication, production resumed immediately. Experiences like this have strengthened my ability to identify root causes under pressure while minimizing costly downtime.

Throughout my career, I have participated in equipment installation, startup, commissioning, dry cycle validation, production qualification, recovery testing, operator support, and ongoing process optimization. I understand the demands of automotive manufacturing and thrive in environments where rapid problem-solving, technical accuracy, and reliable production are essential.

My strengths include FANUC TP programming, robotic cell commissioning, production startup, FANUC iRVision and 3DV integration, robot-to-PLC communications, EtherNet/IP networking, automation troubleshooting, root-cause analysis, manufacturing process optimization, and restoring complex robotic systems to full production quickly and safely. I take pride in understanding how the entire automation system works—not just the robot itself—and using that knowledge to deliver reliable, efficient, and production-ready solutions.