Cold Forming Manufacturing Engineer ( Full-time ) Waco, TX - DK
About The Position
We are seeking a Cold Forming Manufacturing Engineer for a full-time position. This role involves developing, optimizing, and validating machining and cold forming processes for high-volume production. You will establish process windows, analyze forming loads and material flow, and support on-site troubleshooting of production issues at domestic and international manufacturing locations. The position also requires specifying, designing, and qualifying forming dies, punches, rolls, fixtures, and machining tooling, as well as leading pilot builds, PPAP/FAI, and production launches. You will also be involved in new product introduction (NPI) activities, root cause analysis for defects, implementing Lean and Six Sigma methodologies, and partnering with material suppliers. This role requires cross-functional leadership, providing technical support to operations, maintenance, and quality teams, and training operators and engineers.
Requirements
- 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.
Nice To Haves
- 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.
Responsibilities
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
Benefits
- Base Salary - USD $150,000 to $170,000
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What This Job Offers
Job Type
Full-time
Career Level
Senior
