Robotics and Process Control Automation
About The Business: Jeff Gosling Ltd is a UK-based manufacturer specialising in vehicle adaptations for drivers with a disability, designing and producing high-quality products such as hand controls, steering aids and boot hoists. The business operates from Bredbury, Stockport and serves customers nationwide, with a strong reputation for quality and customer service.
Overview: The company has recently invested in a robotic welding system to support increased production demand, particularly for a new high-volume product (boot hoist). While the robot has demonstrated significant efficiency and quality improvements, the business is not yet fully utilising its capabilities due to limited in-house programming expertise and a lack of standardised processes. This internship aims to bridge that gap by embedding robotic programming capability, improving process efficiency, and enabling scalable production.
Desirable Skills: Essential: Undergraduate (2nd/3rd year) in robotics, mechanical engineering, manufacturing engineering, or similar Basic understanding of robotics or automation systems Strong problem-solving and practical engineering skills Desirable: Experience with robotic programming or CNC systems Understanding of welding or fabrication processes Ability to document technical processes clearly Personal Attributes: Proactive and hands-on approach Confidence to work independently on practical tasks Strong communication skills to engage shopfloor teams Expected Outcomes and Success Metrics Operational Outcomes: Fully functioning robotic welding process for A‑Frame Expanded use of robot across multiple components Improved fixturing allowing higher throughput Performance Metrics: Reduction in welding cycle time (target ≤10 minutes per unit) Increase in number of components processed via robot Improved weld consistency and quality Capability Outcomes: Documented SOPs enabling repeatability and scalability Increased confidence and capability among operators Reduced reliance on external support for robot programming
Job Description:
Robotics and Process Control Automation
This project focuses on the application and optimisation of an industrial robotic welding system, including programming, fixturing, and process standardisation to improve manufacturing performance.
Project Goals and Objectives
Develop and validate a fully operational robotic welding programme for the A‑Frame assembly, achieving a stable and repeatable process.
Reduce welding cycle time for the A‑Frame from approximately 20–25 minutes (manual) to ≤10 minutes per unit using the robotic system by the end of the internship.
Design and implement improved fixturing to enable safe multi-part setups (targeting up to four A‑Frames per cycle).
Produce a complete set of Standard Operating Procedures (SOPs) covering robot setup, programming adjustments, and safe operation.
Develop and validate robotic welding programmes for at least 5 additional high-volume components by project completion.
Demonstrate the operating and adjustment of the robotic welding system using the developed SOPs before project handover to welding staff.
Scope of Work, Methods, and Tools
The intern will work closely with the production team to embed robotic welding capability across key products.
Scope of Work:
Review current welding processes and robot setup Optimise and finalise A‑Frame welding programme
Design and refine fixturing to improve efficiency and safety
Develop and test additional product programmes (e.g. screwbars, hinge posts)
Create structured documentation for repeatable use
Support knowledge transfer to operators
Methods:
Iterative testing and refinement of welding programmes
Hands-on collaboration with welders and production staff
Tools and Systems:
Rainbow Robotics RB‑X welding robot (pendant programming)
Welding equipment and fixturing systems
Basic documentation tools (e.g. SOP templates, process maps)
Timeline with Milestones
Weeks 1–2: Induction, safety training, and process familiarisation Review of current robot use and welding operations
Weeks 3–6: A‑Frame programme development and optimisation Fixturing improvements and testing
Weeks 7–9: SOP creation and documentation Initial operator training
Weeks 10–12: Development of additional component programmes
Process refinement and validation
Final Stage: Performance evaluation (cycle time, quality, throughput)
Final report and full handover Intern
Roles and Responsibilities
Develop and optimise robotic welding programmes
Support design and implementation of welding fixtures
Conduct testing and validation of welding processes
Document processes into clear SOPs
Work closely with welders to ensure usability and adoption
Deliver training to operators
Produce a final report summarising outcomes and improvements