While working on a production line, the third joint of a six‑axis robotic arm started stalling during pick‑and‑place cycles.

Identify the root cause and restore full motion without causing downtime for the line.

First, I isolated the joint and checked the error codes via the controller. I verified power supply voltage and inspected the motor driver for overheating. Using a multimeter, I measured resistance on the motor windings and found an open circuit. I swapped the motor with a known good unit to confirm the fault, then replaced the faulty motor and re‑calibrated the joint limits in the controller software. Finally, I ran a series of motion tests and logged performance data.

The joint returned to full speed, cycle time improved by 12%, and the line resumed operation with no further issues.

At my previous job, I was tasked with integrating a new robotic welding cell into an existing assembly line.

Develop and deploy a PLC program that coordinated robot motion, safety interlocks, and conveyor synchronization.

I used Siemens S7‑1500 PLCs and programmed in STEP 7. First, I mapped all I/O points, then created function blocks for robot start/stop, emergency stop handling, and conveyor speed control. I implemented safety interlocks using safety relays and added diagnostic LEDs for operator feedback. After offline simulation, I downloaded the program, performed step‑by‑step testing, and refined timing parameters based on cycle measurements.

The cell achieved a 15% increase in throughput, met all safety audits, and operated without downtime for three months.

During a quality‑inspection run, the robot’s camera occasionally flagged good parts as defective, causing unnecessary rework.

Identify the cause of intermittent false positives and implement a reliable fix.

I started by reviewing the sensor’s data logs to pinpoint when false positives occurred. I noticed a correlation with ambient light changes. I inspected the lighting enclosure and found that the LED ring was aging, causing flicker. I replaced the LEDs with higher‑rated units and added a light‑shielding baffle. Additionally, I updated the vision algorithm’s threshold parameters and introduced a software debounce to filter out spurious readings. Finally, I ran a 48‑hour endurance test to confirm stability.

False positive rate dropped from 8% to less than 0.5%, improving overall yield and reducing rework time by 20%.

Our company was deploying a collaborative robot to work alongside assembly operators for a light‑weight handling task.

Configure the cobot and workspace to meet ISO 10218‑1 and ISO 10218‑2 safety requirements.

I performed a risk assessment following the ISO standard, identifying hazards such as pinch points and unintended motion. I selected appropriate safety-rated monitored stop (SRMS) devices and installed safety light curtains around the shared workspace. I programmed the cobot’s speed and force limits using the manufacturer’s safety-rated controller, and set up a collaborative mode with power and force limiting. I documented all safety measures in a compliance dossier and conducted a joint safety audit with the EHS team.

The cobot passed the external ISO audit on the first attempt, and production started with zero safety incidents in the first six months.

When a new robotic palletizer was installed, the warehouse floor staff had never operated any automation equipment.

Provide effective training so they could safely start, stop, and perform basic troubleshooting without supervision.

I created a concise, visual training manual with step‑by‑step screenshots and safety icons. I held a hands‑on workshop, demonstrating each function, then let each trainee practice under supervision. I used the ‘teach‑back’ method, asking them to explain the steps back to me. I also set up a quick‑reference QR code at the machine for on‑the‑spot guidance.

All operators achieved certification within two days, and the first week saw a 0% safety incident rate and a 10% increase in throughput due to reduced downtime.

Our production line needed high‑precision force feedback, so we added a six‑axis force‑torque sensor to the robot wrist.

Work with the software team to integrate the sensor data into the robot’s motion controller for real‑time compliance control.

I first reviewed the sensor’s communication protocol (EtherCAT) and shared the data sheet with the engineers. Together we defined a ROS‑compatible driver interface. I modified the robot’s PLC program to accept the sensor’s data stream and created a safety filter to reject out‑of‑range values. We performed joint integration tests in a simulation environment before deploying on the live cell, iterating on latency tuning and error handling.

The integrated system achieved sub‑10 ms latency, enabling compliant motion that reduced part deformation by 30% and increased overall yield.