The Process Engineer/ Weld Specialist will be responsible for planning and coordinating new manufacturing projects, optimizing manufacturing processes, layouts, and tooling. Develops welding standards and parameters for existing and new operations, as well as testing protocols and process improvements aimed at reducing costs, enhancing quality, and ensuring compliance with internal and customer requirements.
Duties & Responsibilities:
- Conduct Process PMEA analysis.
- Support development and implementation of control plans.
- Source tooling and equipment; define and verify acceptance criteria.
- Approve tooling and equipment run-offs.
- Identify, track, and validate mistake-proofing initiatives.
- Create and maintain setup instructions.
- Monitor project timelines, approvals, and implementation schedules using Gantt charts.
- Attend customer assembly plant builds as required.
- Follow IATF 16949 and ISO 14001 policies and procedures relevant to the role.
- Establish welding processes and quality parameters for MIG and spot welding operations.
- Assist with programming, maintenance, and optimization of welding paths on FANUC, ABB, Motoman DX100, NX100, XRC, and other robotic controllers.
- Support RFQs, machine run-offs, and equipment acceptance for new welding systems.
- Maintain proper methods and standards for quality and production from spot, MIG, and robotic welders.
- Establish procedures and testing equipment for destructive and non-destructive weld testing in collaboration with Quality.
- Assist with metallurgical studies and research as required.
- Recommend process improvements and support continuous improvement initiatives.
- Prepare cost-reduction proposals with justification.
- Define and maintain equipment standards for the Welding Department.
- Participate in weld fixture design, concept development, and FMEA analysis.
- Support approved welding training programs.
- Develop and recommend welding systems, fixtures, robotics, and consumables.
- Assist with welding dimensional process capability studies for new and existing processes.
- Implement fail-safe welding systems to prevent discrepancies in processes and parts.
- Perform other duties as assigned by the Engineering Manager.
Qualifications:
- B.S. in Engineering or related field (Weld Engineering Technology preferred) or 3–5 years of relevant experience
- Manufacturing engineering experience, preferably in welding/automation
- Proficient in Microsoft Office and AutoCAD
- Familiar with OEM change processes (Ford/GM/Chrysler)
- Experience with robotic/automated welding systems and weld testing (destructive & non-destructive)
- Knowledge of weld fixtures, gage design, parameters, and processes
- Experience with process flows, PFMEAs, and root cause analysis
- Strong analytical, problem-solving, and organizational skills
- Ability to interpret technical documents, perform basic statistical/math analysis, and communicate effectively in reports and procedures