Process Welding Engineer

Pridgeon and Clay•Grand Rapids, MI

14h

About The Position

The Process Welding Engineer works with the Plant to develop and modify current and future programs and processes for robotic, automatic, and semi-automatic welding systems in accordance with company policies. The role combines welding process engineering, equipment and automation support, quality and safety, continuous improvement, project leadership, and personnel management. It also includes leading a multidisciplinary team of Welding Technicians, Maintenance Technicians, and welding or process engineering interns, and supporting weld and assembly departments when leadership is unavailable.

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; ability to apply GD&T 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.
Consistently exhibit appropriate attendance habits and work the hours necessary to perform the job.
Adhere to and support company policies and procedures, including ISO, AIAG, IATF 16949, and safety regulations.

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 workforce planning, recruiting, onboarding, communication, employee development, feedback, performance reviews, and corrective action.
Oversee weld and assembly departments in the absence of a Team Leader or Production Manager.
Maintain a lessons-learned database and lead engineers and process engineering participants in welding and assembly best practices, process control, and daily activities.
Lead project teams, prepare approval and RFQ packages, participate in approval reviews and vendor selection, determine project staffing and resources, establish project plans, evaluate project progress, and recommend process changes.
Provide processing, labor requirements, and capital cost information to Cost Estimating in a timely manner.
Create and modify complex Fanuc robotic welding programs while maintaining welding parameters; modify weld data, torch angles, electrical extension, starting techniques, and other variables.
Create and modify programs for Fronius and Lincoln welding equipment, end-forming equipment, and leak-testing equipment to meet print, gauge, CMM, and leak-rate requirements.
Document welding parameters in Welding Procedure Specifications; troubleshoot processes and equipment; determine weld sequences to improve cycle time and part dimensions.
Select automation, controls, and machine components using cost justification; assist with wiring, installation, and integration of equipment.
Perform preventive maintenance and equipment changeovers; support the design, build, installation, and startup of weld cells, fixtures, sizing and leak-test tools, and auxiliary equipment; manually weld as needed to support production.
Interpret GD&T, welding codes, and specifications; complete weld cross-sectioning; analyze gauge and CMM data and adjust weld fixtures to meet dimensional requirements.
Train and assist operators and welders in assessing weld quality using calipers, visual inspection, and destructive tests; participate in 8D and 5-Why problem-solving and error-proofing activities.
Maintain welding equipment and processes to OSHA, MIOSHA, and company standards; identify potential safety issues and take appropriate action.
Plan and achieve departmental goals for customer concerns, cost of quality, cost savings, safety, and on-time PPAPs; participate in lean and continuous improvement initiatives, including 5S and waste elimination.
Collect data with Process Engineers, provide technical support for lean objectives, communicate plant goals and improvement opportunities, compare productivity and quality metrics, and adjust quality checks as appropriate.
Engineer improvements to process setups, material handling, storage, layouts, work cells, and other plant functions; calculate and submit cost reductions and cost avoidances.
Follow company policies, procedures, quality standards, and safety regulations; maintain an organized work area, communicate accurate and timely information, support teamwork, and model company values and professional conduct.

Benefits

Competitive total compensation.
Comprehensive benefits plan, including premium medical and prescription coverage starting at $5.00 per week for employee coverage.
Dental coverage.
Vision coverage.
401(k) with company match.
Tuition reimbursement.
Safe, team-oriented work environment.
Opportunity to participate in organizational success through continuous improvement and problem-solving events.
Positive work/life balance.
Opportunity for career growth; over 70% of leaders have been promoted from within.