Welding Fixture Maintenance Technician

Overview

This role requires maintaining a high level of availability and precision for robotic and manual welding fixtures to prevent production interruptions and uphold quality standards.

Core Responsibilities

• Carry out routine, predictive, and emergency maintenance on welding fixtures used in robotic and manual operations.
• Examine and repair fixture parts such as clamps, locators, pneumatic cylinders, various sensors, limit switches, guide pins, bushes, and stoppers.
• Troubleshoot fixture problems encountered during production to reduce downtime.
• Perform accurate alignment, calibration, and dimensional checks on fixtures to ensure product consistency.
• Modify fixtures for adaptation to engineering changes, new production models, and process enhancements.
• Collaborate with production, quality control, and welding engineering teams on new product development, trial runs, PPAP, and SOP tasks.
• Maintain detailed records including fixture history logs, maintenance schedules, breakdown documentation, and parts inventory.
• Liaise with the Tool Room for fabrication and machining requirements for replacement fixture parts.
• Implement continuous improvement practices including Kaizen, Poka-Yoke, and Total Productive Maintenance (TPM) to enhance fixture efficiency and reliability.
• Adhere strictly to 5S, safety protocols, ISO 9001, and IATF 16949 standards during all maintenance activities.
• Ensure fixtures are fully operational and production-ready before every shift and equipment changeover.

Required Expertise

• Experience with robotic welding fixtures, preferably from ABB, KUKA, FANUC, or Yaskawa brands.
• Strong knowledge of pneumatic and hydraulic systems, sensors, solenoid valves, and limit switch functionalities.
• Ability to interpret engineering drawings, fixture layouts, and jig designs related to welding operations.
• Practical skills in fixture assembly, fitting, alignment, and troubleshooting tasks.
• Proficiency in measuring with tools such as Vernier Calipers, Height Gauges, Dial Gauges, and Feeler Gauges.
• Fundamental welding and fabrication knowledge.
• Competence in root cause analysis techniques like 5 Why and Fishbone diagrams for problem resolution.
• Effective communication and collaborative teamwork abilities.

Qualifications and Experience

• Minimum qualification of ITI in Fitter, Tool & Die Maker, or Mechanic trade, or a Diploma in Mechanical, Mechatronics, or Tool & Die Engineering.
• At least 2-5 years of prior experience maintaining welding fixtures in automotive or sheet metal manufacturing industries.

Performance Targets

• Maintain fixture availability at 99% or higher.
• Achieve full compliance with preventive maintenance schedules.
• Respond to fixture breakdowns within 30 minutes.
• Complete repair work within 24 hours of reported issues.
• Strive for zero production downtime caused by fixture failure.
• Eliminate customer complaints related to fixtures.
• Initiate at least two Kaizen or improvement projects each quarter.
• Maintain 100% compliance in 5S and safety audits.

Desired Attributes

• Strong analytical reasoning and problem-solving capabilities.
• Ability to react promptly during production breakdowns.
• A high sense of responsibility and ownership for work quality and outcomes.
• Commitment to safety and quality standards.
• A positive mindset focused on continuous improvement.
• Capacity to work efficiently under pressure and meet production deadlines.