Process Welding Engineer

Pridgeon & Clay • Grand Rapids, MI

3d

About The Position

The Welding Process 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 manages and develops a multidisciplinary team, provides technical and project leadership, and supports welding and assembly operations through programming, equipment integration, quality and safety efforts, and continuous improvement.

The position creates and modifies robotic welding programs and programs for welding, end-forming, and leak-testing equipment. It selects and supports automation and controls, assists with equipment design and installation, maintains and improves processes, and uses print, GD&T, gage, and CMM information to help ensure that parts meet requirements. The role also leads projects, coordinates staffing and resources, mentors engineering and technical staff, and contributes to cost, productivity, safety, and quality goals.

Pridgeon and Clay describes itself as one of the largest independent, value-added manufacturers and suppliers of automotive stamped and fine-blanked components in the United States. The company offers competitive total compensation, a comprehensive benefits plan, a safe and team-oriented work environment, opportunities to participate in continuous improvement and problem solving, work/life balance, and career growth.

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 Advanced Product Quality Planning (APQP) process.
• Experience with AIAG Core Tools: APQP, PPAP, FMEA, SPC, and MSA.
• Proficiency with Microsoft Office, including Word, Excel, Project, and PowerPoint.
• Understanding of datum structures and blueprints, including applying GD&T methods to new and existing part prints and interpreting 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.

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 of Welding Technicians, Maintenance Technicians, and Welding or Process Engineering Interns; support headcount planning, recruiting, onboarding, communication, employee development, performance feedback, reviews, and disciplinary actions as needed.
• Oversee weld and assembly departments in the absence of a Team Leader or Production Manager.
• Maintain lessons learned and lead engineers and process engineering participants in welding and assembly best practices, lessons learned, and process control.
• Lead engineering projects, including developing approval packages and RFQ packages, participating in approval reviews, selecting vendors, determining manpower and resources, establishing project plans, and evaluating project progress and methods.
• Provide processing information, labor requirements, and capital cost estimates to the Cost Estimating department as needed.
• Create and modify complex Fanuc robotic welding programs and maintain welding parameters; adjust weld data, torch angles, electrical extension, starting techniques, and other welding variables.
• Create and modify programs for Fronius and Lincoln welding equipment, end-forming equipment and tooling, and leak-testing equipment and tooling to meet print, gage, CMM, and leak-rate requirements.
• Document and maintain welding parameters on Welding Procedure Specifications; troubleshoot processes and equipment and seek permanent fixes.
• Determine weld sequences to improve cycle time and part dimensions and maintain part consistency.
• Select automation, controls, and machine components using cost justification; assist with wiring, installation, and integration of equipment.
• Support the design, build, installation, and startup of weld cells, fixtures, sizing and leak-test machines and tools, and auxiliary equipment.
• Perform preventive maintenance and changeovers on weld fixtures, weld cells, auxiliary equipment, sizing tools, leak-test tools, and poka-yoke devices; recommend improvements to maintenance schedules.
• Manually weld as needed to support production.
• Interpret GD&T, welding codes, and specifications on part prints; complete weld cross-section analysis by cutting, polishing, and etching samples as needed.
• Analyze gage and CMM data and adjust weld fixture details to meet dimensional requirements; train and assist operators and welders in weld-quality checks using calipers, visual inspection, and destructive tests.
• Participate in 8D and 5-Why problem-solving teams and support error-proofing processes.
• Maintain welding equipment and processes in accordance with OSHA, MIOSHA, and company standards; identify potential safety issues and take appropriate action.
• Plan for and achieve departmental goals relating to customer concerns, cost of quality, cost savings, safety, and on-time PPAPs.
• Participate in lean and continuous improvement initiatives, support 5S and lean objectives, collect data, identify and eliminate waste, and communicate plant goals, problems, and improvement opportunities.
• Compare productivity and quality metrics and adjust quality checks to support process quality and productivity.
• Engineer improvements to process setups, material handling, storage, layouts, work cells, and other plant functions; calculate and submit cost reductions and cost avoidances using approved guidelines.
• Follow company policies and procedures, including ISO, AIAG, IATF 16949, and safety regulations; maintain attendance, work-area organization, timely communication, respectful teamwork, professionalism, and company values.
• Travel as needed.

Benefits

• Competitive total compensation.
• Comprehensive benefit plan with premium medical and prescription coverage; employee coverage starts at $5.00 per week.
• Dental coverage.
• Vision coverage.
• 401(k) with company match.
• Tuition reimbursement.
• Safe, team-oriented work environment with a leadership team that values employee input.
• Opportunity to participate in continuous improvement and problem-solving events.
• Positive work/life balance.
• Career growth opportunities; the company states that over 70% of its leaders have been promoted from within.

What This Job Offers

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