Robotic and Controls Manager

This position is for our new facility in Orangeburg South Carolina Position Summary The Robotic & Controls Manager leads the robotics, controls, and automation function for automotive ladder-frame, subframe, cross member, 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 Responsibilities Team 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 Continued Controls 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,…