ROBOTIC WELDING FOREMAN

The Caldwell Group Inc; Rockford (IL); On-site; USD 64,000 - 79,000; Full time

Job summary

The Caldwell Group Inc in Rockford, IL is seeking a Robotic Welding Foreman to lead our robotic welding team and oversee daily operations. You will combine hands-on offline programming with leadership to keep production on schedule and quality high.

You will work across welding cells, coordinate with engineering and maintenance, and drive safety and continuous improvement initiatives in a dynamic manufacturing environment.

Qualifications

• 5+ years robotic welding experience; 2+ years in lead/supervisory role.
• Hands-on experience with offline programming software.
• Strong reading of blueprints, weld symbols, and specs.

Responsibilities

• Supervise welding operators, programmers, and technicians.
• Set clear performance expectations and support skill development.
• Foster safety, accountability, and continuous improvement.

Skills

Offline programming

Team leadership

Production planning

Troubleshooting

Quality focus

Education

Associate degree or technical cert

Tools

Intelli Path

DTPS

Miller welding equipment

Job description

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ROBOTIC WELDING FOREMAN

ADMINISTRATION Regular Full Time Management Rockford, IL, US

Salary: $71,500.00 Annually

Position Summary

We are seeking an experienced Robotic Welding Supervisor to lead our robotic welding team and oversee daily operations across our Miller-equipped welding cells. This person will combine hands-on technical expertise in offline programming with strong leadership skills to keep production on schedule, quality high, and the work environment safe. The ideal candidate is comfortable on the shop floor, in the programming environment, and in production planning meetings.

Key Responsibilities

• Supervise, schedule, and mentor robotic welding operators, programmers, and technicians
• Set clear performance expectations, conduct reviews, and support skill development and cross-training
• Foster a culture of accountability, safety, and continuous improvement

Production Coordination

• Plan and prioritize daily and weekly production schedules to meet delivery targets
• Coordinate with engineering, quality, maintenance, materials, and shipping to minimize downtime and bottlenecks
• Monitor cell output, cycle times, and efficiency metrics, and act on variances
• Manage changeovers, fixture setups, and new part launches

Offline Programming and Process Development

• Create, validate, and optimize robot weld programs using offline programming software through Intelli Path (cloud-based offline programming software) and DTPS (Desktop Programming and Simulation Software) (e.g., Fanuc ROBOGUIDE, Yaskawa MotoSim, ABB Robot Studio, or equivalent)
• Simulate weld paths, reach, and cycle times to reduce downtime on the production floor
• Review part drawings and weld specifications to develop efficient programs and fixturing strategies
• Maintain a controlled library of weld programs, revisions, and documentation

Miller Welding Cell Management

• Oversee operation, setup, and troubleshooting of Miller robotic welding systems, including power sources, wire feeders, torches, and associated automation
• Coordinate preventive maintenance and consumable management to maximize uptime
• Adjust weld parameters (voltage, wire feed speed, travel speed, gas flow) to meet procedure and quality requirements
• Evaluate and recommend equipment upgrades or process improvements or new capital projects.

Quality Assurance

• Ensure welds meet applicable standards and customer specifications (e.g., AWS D1.1, D1.2, D17.1, or relevant codes)
• Work with Quality to inspect, document, and resolve defects, and lead root-cause analysis and corrective actions
• Maintain accurate production, inspection, and traceability records

Safety and Compliance

• Enforce safety procedures, including lockout/tagout, robot cell guarding, PPE, and fume extraction requirements
• Conduct safety audits, toolbox talks, and incident investigations
• Ensure compliance with OSHA, company policies, and applicable robotic safety standards (e.g., ANSI/RIA R15.06)

Required Qualifications

• 5+ years of robotic welding experience, with at least 2 years in a lead or supervisory role
• Hands-on experience with offline programming software
• Working knowledge of Miller robotic welding equipment and MIG/GMAW processes
• Ability to read and interpret blueprints, weld symbols, and technical specifications
• Strong understanding of weld quality, distortion control, and fixturing
• Proven leadership, communication, and problem-solving skills
• Familiarity with safety standards for robotic cells

Preferred Qualifications

• Associate degree or technical certification in welding, robotics, or manufacturing technology
• Certified Welding Inspector (CWI) or Robotic Arc Welding Certification (AWS or equivalent)
• Offline programming and weld path optimization through Intelli Path (cloud-based offline programming software) and DTPS (Desktop Programming and Simulation Software)
• Experience with Lean manufacturing, 5S, or Six Sigma
• Experience with ERP/MES systems and production metrics tracking
• Experience with collaborative robots or laser seam tracking and touch-sensing systems

Skills and Competencies

• Offline programming and weld path optimization
• Team leadership and conflict resolution
• Production planning and scheduling
• Troubleshooting robotic and weld process issues
• Attention to detail and commitment to quality

Physical Requirements and Work Environment

• Work in a manufacturing environment with exposure to noise, heat, welding fumes, and moving equipment
• Ability to stand and walk for extended periods and lift to 50 lbs.
• Required PPE, including safety glasses, hearing protection, and welding protective gear as needed
• Flexibility to support extended hours or additional shifts as production requires