Engineering Technician – Spring Manufacturing & WAFIOS Equipment

Flex•Libertyville, IL

28d•$34 - $47•Onsite

About The Position

Flex is seeking an experienced Engineering Technician to support the production, setup, troubleshooting, and continuous improvement of CNC spring manufacturing processes. This role is responsible for supporting high-volume medical device spring production using WAFIOS spring coiling equipment and associated secondary operations. The Engineering Technician will work closely with Engineering, Quality, Maintenance, and Production teams to optimize processes, improve equipment performance, troubleshoot manufacturing issues, and support operator training.

Requirements

8+ years of experience in spring manufacturing, precision manufacturing, or automated production equipment.
Hands-on experience with WAFIOS spring coiling machines (FUL, FMU, or equivalent models preferred).
Strong understanding of spring manufacturing principles, including: Free length, Outside diameter (OD), Pitch, Spring rate, Load testing, Helix and cast, Material behavior.
Experience troubleshooting CNC spring coiling equipment and related automation systems.
Ability to interpret engineering drawings, blueprints, specifications, and tooling designs.
Strong mechanical aptitude and machine setup experience.
Knowledge of precision measurement equipment and statistical process control methods.
Experience with preventive maintenance and equipment reliability programs.
Familiarity with FDA-regulated, medical device, or highly regulated manufacturing environments.
Proficiency with PC-controlled manufacturing equipment and machine interfaces.
WAFIOS machine programming and setup
Spring tooling adjustments and optimization
Mechanical troubleshooting
Electrical troubleshooting including: Motor overloads, Sensors, Fuses, Broken wires, Fault diagnosis
Pneumatic systems
Root cause analysis
Statistical process control (SPC)
Process validation
Technical training and mentoring
Continuous improvement methodologies

Responsibilities

Set up, adjust, operate, and troubleshoot WAFIOS CNC spring coiling machines including tooling, guides, coiling points, pitch tools, and cutoff systems.
Support production of compression, extension, and torsion springs used in medical device applications.
Analyze spring characteristics such as free length, outside diameter, pitch, spring rate, squareness, and load requirements.
Diagnose and resolve manufacturing issues related to spring geometry, machine setup, tooling wear, material variation, and equipment performance.
Perform first-piece inspections and process verifications using calipers, micrometers, optical measurement systems, force testers, and spring load testers.
Investigate process deviations and implement corrective actions to improve product quality and manufacturing efficiency.
Conduct engineering trials, machine studies, DOE activities, and capability evaluations.
Collaborate with engineers to optimize spring designs, manufacturing methods, tooling concepts, and machine settings.
Support process validation activities, including IQ/OQ/PQ and process capability studies.
Develop and document machine setup standards, troubleshooting guides, and best practices.
Perform preventive maintenance and replacement of worn machine components.
Troubleshoot mechanical, electrical, pneumatic, and servo-controlled machine systems.
Analyze production data and equipment performance trends to identify opportunities for continuous improvement.
Assist with startup, qualification, and commissioning of new spring manufacturing equipment.
Train operators, spring makers, and technicians on machine setup, operation, troubleshooting, and inspection procedures.
Support root cause investigations and implementation of corrective and preventive actions (CAPA).