Process Welding Engineer

Pridgeon & Clay Inc • Grand Rapids, MI

5d

About The Position

The Process Welding Engineer interfaces with the plant to develop and modify existing and upcoming programs and processes for robotic, automatic, and semi-automatic welding systems in accordance with company policies. The role combines welding process development and programming with equipment and project engineering, quality and safety oversight, continuous improvement, and leadership of welding and process engineering personnel.

The engineer manages a multidisciplinary team that may include Welding Technicians, Maintenance Technicians, and Weld or Process Engineering Interns; leads projects and team activities; and supports the Engineering Manager. The position develops and modifies robotic welding, welding equipment, end-forming, and leak-testing programs; selects, installs, integrates, maintains, and improves equipment; and works with production and quality teams to meet customer specifications and dimensional requirements.

The role also supports workforce planning, recruiting, onboarding, employee development and performance reviews, project planning and resources, cost estimating, problem solving, lean initiatives, safety, and communication across the plant. The posting describes a safe, team-oriented work environment and opportunities to contribute to continuous improvement and organizational success.

Requirements

• Bachelor's degree in engineering with an emphasis in welding.
• At least one year of engineering experience in a manufacturing environment, including launching new products, sourcing weld fixtures, and producing standardized work.
• Experience with machine-build project management, including quoting machine and labor capacities for new jobs and developing poka-yoke sensors and devices to prevent or detect defects; ability to drive projects to completion.
• Experience programming robotic welders such as Fanuc, ABB, Panasonic, or Motoman.
• Ability to develop consistent weld parameters and processes, with experience using statistical process analysis to ensure consistent weldments.
• Experience implementing continuous improvement.
• Exposure to the APQP process.
• Experience with AIAG Core Tools: APQP, PPAP, FMEA, SPC, and MSA.
• Computer proficiency in Microsoft Office, including Word, Excel, Project, and PowerPoint.
• Understanding of datum structures and blueprints; ability to apply GD&T methods to new and existing part prints and interpret CMM layout results.
• Experience with problem-solving methods such as 8D and 5 Why, and with lean initiatives.
• Ability and willingness to work in a team-based environment and travel.
• Excellent communication and leadership skills.
• Excellent work record, including attendance.
• Ability to manage and lead welding and process engineering staff, technicians, and interns, and to carry out associated workforce and project responsibilities as described in the essential functions.
• Ability to interpret customer welding codes and specifications and support weld quality, equipment, safety, and production requirements.

Nice To Haves

• Previous experience in a metal-forming manufacturing environment.
• Five or more years of engineering experience in a manufacturing environment.
• Knowledge of SolidWorks and Minitab software.

Responsibilities

• Manage a multidisciplinary team consisting of Welding Technicians, Maintenance Technicians, and Weld or Process Engineering Interns, working with engineering leadership throughout the company.
• Participate in headcount forecasting; propose solutions for workforce fluctuations; and create requisitions, recruit, interview, hire, and onboard team members as needed.
• Lead team communication through meetings and status updates, communicate with coworkers and management, and inform team members of technical and training opportunities.
• Provide employee performance feedback, address unacceptable performance using the Company Employee Handbook, and complete annual performance reviews with action plans where needed.
• Oversee weld and assembly departments in the absence of a Team Leader or Production Manager.
• Maintain a lessons-learned database and share best practices, lessons learned, and process-control practices with Welding Engineers and process engineering participants.
• Assist the Engineering Manager by leading Weld Engineers in projects and daily activities as needed; provide project-team leadership, help develop approval packages and RFQ packages, participate in approval reviews, and perform vendor selection.
• Determine project manpower and resources, coordinate with departments, establish and implement project plans, ensure staff have necessary skills, evaluate ongoing projects, and recommend or direct changes to methods and processes.
• Provide processing information, labor requirements, and capital costs to Cost Estimating in a timely manner.
• Apply engineering training to improve the effectiveness of the Engineering Group and the company's welding and assembly product lines.
• Create and modify complex Fanuc robotic welding programs while maintaining welding parameters and adjusting weld data, torch angles, electrical extension, starting techniques, and other variables.
• Create and modify Fronius and Lincoln welding-equipment programs to produce welds meeting customer codes and specifications.
• Create and modify programs for end-forming equipment and tooling to meet gage or CMM requirements, and for leak-testing equipment and tooling to meet required leak rates.
• Document and maintain welding parameters in Welding Procedure Specifications; troubleshoot processes and equipment; and determine weld sequences to improve cycle time and dimensional consistency.
• Select automation components, controls, and equipment using cost justification, including robots, pick-and-place units, and conveyors.
• Assist with wiring, installation, and integration of internally and externally built equipment.
• Perform preventive maintenance on weld fixtures, weld cells, and auxiliary equipment, and recommend improvements to preventive-maintenance schedules.
• Assist in the design, build, installation, and startup of weld cells, fixtures, sizing and leak-test machines and tools, and auxiliary equipment.
• Complete equipment changeovers for weld fixtures, sizing tools, leak-test tools, poka-yokes, and auxiliary equipment; manually weld as needed to support production.
• Interpret GD&T and welding codes and specifications on part prints; perform weld cross-sectioning by cutting, polishing, and etching samples as needed.
• Analyze gage and CMM data and adjust weld-fixture details to meet dimensional requirements; assist and train operators and welders in assessing weld quality using calipers, visual inspection, and destructive tests.
• Participate in 8D and 5-Why problem-solving teams and support error-proofing through 8D problem solving.
• Maintain weld equipment and processes to OSHA, MIOSHA, and company standards; identify potential safety issues and take appropriate action.
• Plan for and achieve departmental goals concerning customer concerns, cost of quality, cost savings, safety, and on-time PPAPs.
• Participate in continuous-improvement and lean initiatives, identify and eliminate waste, provide leadership and technical support for 5S and lean objectives, and assist Process Engineers with data collection.
• Communicate plant goals, problems, and improvement opportunities to plant operations; compare productivity and quality metrics and adjust quality checks to support quality and productivity.
• Engineer improvements to process setups, material handling, storage, layouts, work cells, and other functions affecting plant performance; calculate and submit cost reductions and cost avoidances using approved guidelines.
• Maintain appropriate attendance and an organized, efficient work area; adhere to and support company policies, procedures, standards, and safety regulations.
• Provide accurate and timely feedback to coworkers and management, communicate effectively, treat coworkers with dignity and respect, model professionalism and integrity, and support company values.

Benefits

• Competitive total compensation.
• Comprehensive benefits plan, including medical and prescription coverage with employee coverage starting at $5.00 per week.
• Dental insurance.
• Vision insurance.
• 401(k) with company match.
• Tuition reimbursement.
• Safe, team-oriented work environment.
• Positive work/life balance.
• Opportunity for career growth; the posting states that over 70% of company leaders have been promoted from within.

What This Job Offers

• Job Type: Full-time
• Career Level: Manager