Process Engineer

Salamander Solutions Inc.•Houston, TX

1d•Onsite

About The Position

Process Engineer – Downhole Heater Manufacturing & Roll Reduction Operations Salamander Solutions is seeking a Process Engineer – Downhole Heater Manufacturing & Roll Reduction Operations to support and optimize manufacturing processes related to the production of advanced heater systems for oil & gas applications. This role is responsible for developing, monitoring, and improving all process steps associated with heater tube forming, roll‑reduction mill operations, heat treatment, assembly, and quality control. The Process Engineer will work closely with manufacturing, mechanical engineering, operations, and quality teams to drive efficiency, ensure product consistency, and maintain the highest standards of safety and reliability. This position requires on-site presence.

Requirements

Bachelor’s degree in process engineering, mechanical engineering, manufacturing engineering, materials engineering, or related technical discipline.
5–10 years of experience in process engineering, preferably in metal forming, tube production, hot‑work processes, or industrial manufacturing.
Experience with roll‑reduction mills, rotary reduction, swaging, drawing, or similar forming equipment is strongly preferred.
Strong understanding of metallurgy, especially microstructure changes under deformation and heat.
Hands‑on experience conducting root‑cause analysis, developing corrective actions, and improving manufacturing processes.
Proficiency with data analysis tools, SPC, capability studies, and statistical modeling.
Knowledge of manufacturing quality systems, tolerance control, and inspection practices.
Ability to create detailed process documentation and interpret engineering drawings.
Experience supporting production floor operations, including troubleshooting equipment and process variations.
Strong cross‑functional communication and collaboration skills.
High attention to detail, strong analytical abilities, and a continuous‑improvement mindset.

Responsibilities

Develop, implement, and optimize manufacturing processes for roll‑reduction, tube forming, heat treatment, machining, and final assembly of heater systems.
Create and maintain process documentation, including process flow diagrams, work instructions, routings, operating parameters, and quality checkpoints.
Analyze process performance data to identify inefficiencies, scrap drivers, dimensional drift, or equipment variability.
Define and control process parameters such as reduction ratios, heating cycles, lubrication requirements, speeds/feeds, and thermal‑mechanical limits.
Lead root‑cause investigations for process deviations, non‑conformance, or equipment‑related manufacturing issues.
Develop corrective and preventive action plans (CAPA) in coordination with Quality and Operations teams.
Collaborate with Mechanical Engineers and Designers to ensure manufacturability of new products, tooling, and process changes.
Support the introduction of new tooling and equipment, including commissioning, validation, and capability assessments.
Participate in PFMEA development, identifying process risks and implementing mitigation measures.
Conduct process capability studies, SPC analysis, and statistical evaluations to improve consistency and reduce variability.
Drive continuous improvement initiatives, including cycle‑time reduction, cost savings, waste reduction, and safety enhancements.
Monitor and optimize heat treatment and metallurgical processes to ensure correct material properties and dimensional stability.
Support training efforts for operators, technicians, and engineering staff on new processes or process updates.
Ensure compliance with internal quality standards, manufacturing specifications, and safety requirements.