Responsibilities:
Machining & Cold Forming Process Engineering
- Develop, optimize, and validate machining and cold forming processes for high-volume production.
- Establish process windows using DOE, SPC, and capability studies (Cp/Cpk).
- Analyze forming loads, material flow, tool wear, and machining performance to improve quality and throughput.
- Support on-site troubleshooting of production issues at domestic and international manufacturing locations.
Tooling & Equipment:
- Specify, design, and qualify forming dies, punches, rolls, fixtures, and machining tooling.
- Lead on-site die verifications/tests, machine acceptance, and production ramp-ups.
- Work directly with OEMs and tool shops to commission new equipment and debug tooling.
- Drive tool life improvement and maintenance strategies across multiple facilities.
New Product Introduction (NPI):
- Support NPI activities across multiple plants, including feasibility reviews and process selection.
- Lead pilot builds, PPAP/FAI, and production launches on-site.
- Ensure manufacturing readiness through standardized processes and documentation.
Quality & Continuous Improvement:
- Lead root cause analysis and corrective actions for machining and forming defects.
- Implement Lean and Six Sigma methodologies to reduce scrap, variation, and downtime.
- Standardize best practices across sites through process documentation and training.
Materials & Supplier Development:
- Partner with material suppliers on wire, bar, heat treatment, and coatings.
- Conduct supplier process audits and capability assessments.
- Support sourcing decisions and cost-reduction initiatives through technical expertise.
Cross-Functional Leadership:
- Provide hands-on technical support to operations, maintenance, and quality teams.
- Train operators and engineers during launches and process changes.
Act as a technical liaison between plants, suppliers, and corporate engineering.
Qualifications:
- Bachelor’s degree in manufacturing, mechanical, or industrial engineering (or similar disciplines).
- 10+ years of experience in machining and/or cold forming environments.
- Strong understanding of metal forming physics, machining fundamentals, and tooling.
- Proven experience supporting production in multi-site or supplier-facing roles.
- Willingness and ability to travel up to 75%, including extended on-site assignments.
Preferred Qualifications:
- Experience with high-volume cold heading, progressive forming, or precision machining.
- Knowledge of steels, alloys, heat treatment, and surface coatings.
- Experience working with global suppliers or international manufacturing plants.
- Six Sigma Green Belt or equivalent.
Work Environment & Travel:
- 75% travel required to manufacturing plants, tool shops, and supplier locations.
- Hands-on, shop-floor–focused role with extended time on-site during launches and issue resolution.
- Remaining time split between home office and engineering documentation.
Security Clearance Required: No
Visa Candidate Considered: No
Compensation:
Base Salary - USD $150,000 to $170,000