Process Engineer – First Shift

Tuffaloy Products is a leading manufacturer of resistance welding consumables. The resistance welding process is a cost-effective metal joining process used in automotive, industrial, and aerospace manufacturing. Tuffaloy is a privately held business that has been in operation for 85 years. Our Products are produced at our 50,000 sq/ft climate-controlled facility utilizing state-of-the-art CNC Lathes, mills, presses and cold formers. Tuffaloy has a family-oriented culture and flat organizational structure. Tuffaloy is committed to continually challenging itself to maintain its market position and grow. We are looking for a self-driven, team player to join Tuffaloy's manufacturing team. The primary responsibilities of this position will be to provide first-shift technical and operational support focused on setup reduction and process improvement. This position bridges engineering, machining, quality, and lean initiatives by supporting operators, improving machining processes, standardizing setups and tooling, and ensuring work flows efficiently through the shop.

The primary objective of this role is process improvement. Success is measured by reduced setup times, increased machine uptime, 5S adherence, better material and tool flow, and increased operator capability and confidence.

Reporting

· Reports to Manufacturing Manager

Key Responsibilities

· Provide hands-on technical support for twin-spindle and Swiss style CNC lathe operations (Star and Nakamura preferred), including troubleshooting process and machine issues

· Troubleshoot Fanuc CNC controls, including part programs, tooling, offsets, and multi-spindle logic (some hand programming will be required)

· Act as an escalation resource during complex or stalled setups, alarms, or programming challenges to minimize downtime

· Monitor and support reduction of setup times, identifying excessive durations and process variability

· Support 5S implementation and sustainment, including tool organization, kitting standards, and workplace audits

· Occasionally support machinists with tool kitting and material prep for upcoming jobs to support efficient changeovers and schedule adherence

· Design, machine, or modify tooling and fixtures to improve repeatability, safety, and process capability

· Communicate equipment issues and coordinate with Maintenance to resolve 

· Assist with new part process including program and tooling validation

· Support SOP development and requirements

Process Engineer – First Shift  

Required Qualifications

· 7+ years of experience with CNC machining, specifically:

               o Hand programming CNC lathes

               o Fanuc controls (required)

               o Twin-spindle lathe experience (Star and Nakamura strongly preferred)

· 2+ years of experience in process engineering, lead machinist, or advanced setup support role

· Strong understanding of setup practices, tooling, offsets, and multi-axis/multi-spindle machining concepts

· Proven experience with lean manufacturing principles

· Solid understanding of in-process inspection methods and quality fundamentals

· Strong problem-solving skills and the ability to work calmly and effectively in a production environment

· Able to lift 50 lbs. on occasion

· Requires constant standing, walking, sitting, and bending throughout the workday

Preferred Qualifications

· Familiarity with cycle-time analysis, setup reduction (SMED), and continuous improvement projects

· Experience designing or modifying fixtures and tooling to improve machining processes

· Ability to work cross-functionally with Quality, Maintenance, Scheduling, and Engineering

· Proficient with Microsoft Office Suite (Word, Excel)

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