Robotic and Controls Manager

This position is for our new facility in Orangeburg South CarolinaPosition SummaryThe Robotic & Controls Manager leads the robotics, controls, and automation function for automotive ladder-frame, subframe, crossmember, and chassis assembly operations. The role is accountable for team performance, technical standards, equipment readiness, and reliable automated production from equipment design through commissioning, launch, and ongoing optimization.This is a hands-on leadership role responsible for robotic welding, PLC and HMI systems, equipment integration, and technical problem solving. The manager works with Engineering, Production, Maintenance, Quality, Tooling, IT, Project Management, suppliers, and OEM customers to achieve safety, quality, delivery, and cost objectives.Key ResponsibilitiesTeam Leadership and Resource Management• Lead and develop robotics and controls engineers and technical personnel; establish priorities, assign work, and review performance and training needs.• Plan staffing, contractor support, and technical coverage for installation, commissioning, ramp-up, and production support.• Manage approved automation budgets, project expenditures, and improvement proposals; monitor supplier scope, cost, timing, and deliverables.• Maintain a technical skills matrix and ensure effective knowledge transfer to Production and Maintenance teams.Robotics and Automated Assembly• Lead robotic welding and automation strategy, cell design reviews, equipment specifications, feasibility assessments, and integration for structural automotive assemblies.• Oversee robot programming and optimization, with emphasis on KUKA and familiarity with FANUC and ABB platforms.• Coordinate welding paths, robot motion, tooling interfaces, weld parameters, seam tracking, and vision systems with Welding Engineering and Quality.• Improve robot utilization, cycle time, line balancing, and equipment effectiveness while protecting weld quality and process capability.Key Responsibilities ContinuedControls and System Integration• Own PLC, HMI, safety controls, servo, drive, and industrial network standards; review controls architecture and supplier software before acceptance.• Lead programming, integration, and troubleshooting of Allen-Bradley, Siemens, and Beckhoff systems according to installed equipment requirements.• Ensure effective communication between robots, PLCs, welding power sources, fixtures, sensors, vision systems, and production data systems.• Control software changes, program backups, version history, access permissions, and recovery procedures in coordination with IT and Maintenance.• Ensure electrical drawings, I/O lists, robot programs, PLC and HMI files, and equipment manuals remain accurate and available.Equipment Launch and Supplier Management• Lead robotics and controls activities from concept through Start of Production; define milestones, readiness criteria, and escalation plans.• Review integrator proposals and technical specifications; coordinate factory and site acceptance tests, equipment buy-offs, and closure of open issues.• Coordinate installation, debugging, commissioning, pilot builds, Run-at-Rate, production validation, and ramp-up with the project team.• Verify cycle time, capacity, functionality, documentation, training, and spare-parts readiness before equipment handover.Safety Quality and Process Control• Ensure risk assessments, guarding, interlocks, emergency stops, and safety functions are reviewed and validated with HSE and qualified technical personnel before release.• Ensure the team follows safe work practices, energy-isolation procedures, and controlled authorization for equipment and software changes.• Contribute automation inputs to process flows, PFMEAs, control plans, standardized work, work instructions, and APQP and PPAP activities.• Implement and validate error-proofing, traceability, and process monitoring; support quality investigations and corrective actions.Production Support and Continuous Improvement• Lead escalation and recovery for major robotics and controls failures; coordinate containment, root-cause analysis, and permanent corrective actions.• Partner with Maintenance on preventive and predictive maintenance, critical spare parts, obsolescence, and equipment recovery plans.• Track downtime, OEE, weld quality, scrap, and cycle time; prioritize improvements using production data and structured problem solving.• Report technical risks, launch readiness, budget status, and improvement results to plant leadership and cross-functional stakeholders.Required Qualifications• Bachelor’s degree in Electrical Engineering, Mechatronics, Robotics, Manufacturing Engineering, Mechanical Engineering, or a related field.• At least five years of relevant experience in automotive robotic welding, controls, or automated assembly, including demonstrated technical team or project leadership.• Experience in high-volume ladder-frame, subframe, BIW, chassis, or structural automotive manufacturing.• Hands-on experience with industrial robot programming, PLC and HMI troubleshooting, equipment integration, and automated production support.• Experience with equipment specifications, supplier technical reviews, commissioning, production launch, and structured problem solving.• Ability to plan resources, manage priorities and budgets, and communicate effectively with technical teams, suppliers, customers, and plant leadership.Preferred Qualifications• Previous management responsibility for robotics, controls, or automation teams in a Tier-1 automotive supplier.• Greenfield plant launch experience and direct involvement in equipment acceptance and production ramp-up.• Strong KUKA experience and familiarity with FANUC or ABB robots, simulation tools, and offline programming.• Experience with OEM requirements and global manufacturing operations.Technical Skills• Robotics and welding: KUKA, FANUC, ABB; MIG/MAG and resistance welding; familiarity with projection, laser, and stud welding where applicable.• Controls: Allen-Bradley Studio 5000, Siemens TIA Portal, Beckhoff, safety PLCs, HMI systems, servo systems, industrial networks, and electrical schematics.• Manufacturing and quality: APQP, PPAP, PFMEA, control plans, OEE, capacity analysis, GD&T, SPC, MSA, and error-proofing; familiarity with IATF 16949 and ISO 9001 systems.• Engineering tools: ability to review CAD layouts and robotic simulation outputs; familiarity with AutoCAD, CATIA, NX, SolidWorks, Process Simulate, DELMIA, RoboGuide, RobotStudio, or KUKA.Sim.Key Performance IndicatorsSafety performance; equipment OEE and availability; cycle time and capacity achievement; launch milestone completion; first-pass yield and weld quality; scrap and downtime reduction; MTTR and MTBF; automation project budget performance; training and skills development.Desired CompetenciesTeam leadership and accountability; analytical problem solving; planning and prioritization; clear communication; cross-functional collaboration; customer focus; sound technical judgment; continuous improvement; ability to lead through launch pressures.Travel RequirementsUp to 25% domestic and international travel for equipment buy-offs, supplier support, launch activities, and customer meetings. #J-18808-Ljbffr SODECIA - AAPICO JV LLC