Manufacturing Process Engineer -Stainless Steel Carbody Manufacturing

Segula Technologies USA Inc•Hornell, NY

2d•Onsite

About The Position

SEGULA Technologies is seeking a Manufacturing Process Engineer with deep expertise in stainless-steel carbody shell manufacturing to support and improve production operations in a high-complexity rail/transportation manufacturing environment This role is heavily focused on stainless-steel fabrication, welding process optimization, deformation control, tooling effectiveness, and industrialization of engineering changes on the shopfloor. The ideal candidate will bring hands-on experience in stainless-steel structural assembly, particularly in environments involving carbody shells, welded assemblies, fixtures, and dimensional control This is a shopfloor-driven manufacturing engineering role focused on process improvement and production support. It is not a design engineering or procurement role.

Requirements

Minimum 5+ years of experience specifically in stainless-steel carbody shell manufacturing or equivalent heavy stainless-steel welded structural manufacturing.
Strong hands-on experience in stainless-steel fabrication, welding, structural assembly, and shopfloor manufacturing process improvement.
In-depth knowledge of MIG/TIG welding processes for stainless steel, including weld behavior, heat input effects, and distortion/deformation control.
Strong experience with: Deformation control / dimensional stability in stainless-steel welded assemblies
MTM, time studies, and line balancing
PFMEA and process risk assessment
Root Cause Analysis and structured problem-solving tools (8D / PDCA)
Proven ability to write and maintain: Work Instructions
Manufacturing process documentation
Digital records for traceability and change control
Strong shopfloor presence with the ability to support operators, supervisors, and production teams in a fast-paced manufacturing environment.

Nice To Haves

Experience in railcar / rail transportation / stainless-steel carbody shell manufacturing highly preferred.
Lean Manufacturing certification.
Green Belt or equivalent continuous improvement / problem-solving certification.
Prior experience supporting welded structural stainless-steel assemblies with tight dimensional and cosmetic require

Responsibilities

Lead and implement process improvements specifically related to stainless-steel carbody shell manufacturing, including fabrication, fit-up, welding, and structural assembly.
Analyze and improve stainless-steel production flow, with a focus on reducing cycle time, improving repeatability, and increasing throughput.
Apply industrial engineering methodologies to improve efficiency, consistency, and quality in stainless-steel fabrication processes.
Support and optimize MIG/TIG welding processes for stainless-steel assemblies, ensuring robust process control and high-quality weld outcomes.
Drive initiatives to reduce and control heat distortion, warpage, shrinkage, and deformation in stainless-steel welded structures.
Develop and implement best practices for weld sequencing, clamping strategy, fixture usage, and dimensional stabilization.
Collaborate with production teams to resolve weld-related quality issues, fit-up challenges, and structural dimensional concerns.
Evaluate and improve tooling, jigs, fixtures, and clamping systems used in stainless-steel carbody assembly and welding.
Conduct detailed assessments of tooling performance to ensure proper alignment, repeatability, and deformation control during manufacturing.
Recommend and implement fixture or tooling modifications to support improved part accuracy, process capability, and operator efficiency.
Lead the industrialization of Engineering Change Orders (ECOs) into the manufacturing environment for stainless-steel structures and assemblies.
Assess manufacturing impact of engineering changes, including effects on weld sequence, tooling, work instructions, cycle time, and quality controls.
Ensure all engineering changes are successfully translated into shopfloor execution with minimal disruption to production.
Create, update, and maintain detailed Work Instructions (WIs) and manufacturing process documentation for stainless-steel fabrication and welding operations.
Ensure documentation reflects best practices for fit-up, weld preparation, sequence, deformation control, inspection points, and tooling usage.
Maintain digital traceability of all process changes, updates, improvements, and measurable outputs.
Provide direct, hands-on shopfloor support to manufacturing teams for stainless-steel carbody operations.
Troubleshoot production issues related to fit-up, welding quality, dimensional variation, process flow, and assembly repeatability.
Partner closely with production, quality, and manufacturing leadership to ensure stable execution of stainless-steel manufacturing processes.