Offline Programming (OLP) has emerged as a transformative tool in industrial robotics, enabling efficient and precise automation of manufacturing tasks. This study presents a case study on the implementation of OLP for automating a robotic welding process using a collaborative robot and simulation software. With the help of simulation-based programming, the study successfully optimized welding sequences and generated robot code without the need for extensive manual teaching. Compared to traditional online programming, which can take weeks to complete, the OLP approach reduced programming time to just a few hours, significantly improving efficiency and reducing production downtime. Additionally, the system demonstrated the capability to accommodate varying workpiece placements within the robot’s work envelope, eliminating the need for individual programming of multiple start positions. Experimental validation confirmed the accuracy and reliability of the generated code, ensuring seamless execution of welding tasks. The findings highlight the advantages of OLP in industrial automation, particularly in enabling flexible workpiece positioning without reprogramming, reducing programming effort through automated code generation, and achieving sub-millimeter precision between simulation and physical execution.