Welding Process Engineer

Staffline; Cheltenham; On-site; GBP 46,000 - 48,000; Full time

Job summary

Staffline in Cheltenham is seeking a WeldingProcess Engineer to develop, optimise and maintain automated welding processes for high-quality production and NPI. You will define welding parameters and ensure robust procedures.

The role focuses on process robustness, continuous improvement, and technical support across production. You'll lead root cause analysis, support audits, and collaborate with Design Engineering, Quality and Supply Chain to improve system capability and weld reliability.

Qualifications

• Strong technical knowledge of mechanical engineering processes.
• Proven experience with automated or robotic welding systems.
• Ability to interpret engineering drawings, weld symbols, and specifications.

Responsibilities

• Develop, validate, and optimise mechanical engineering processes for production and new product introduction.
• Define and control critical welding parameters (current, travel speed, wire feed, shielding gas, heat input).
• Establish robust procedures and operating windows to ensure repeatable, high-quality welds.
• Support internal and external audits relating to welding processes and special process controls.
• Provide technical support to production to resolve weld quality issues; lead root cause analyses.
• Specify, commission, and validate automated welding equipment, fixtures, and tooling.
• Work with suppliers/integrators to improve system capability and uptime.
• Drive continuous improvement using Lean six-sigma principles (Cp/Cpk).
• Collaborate with Design Engineering to influence manufacturability and weld joint design.
• Provide training and technical guidance to operators, technicians, and inspectors.

Skills

Mechanical engineering processes

Automated/robotic welding systems

Welding parameters interpretation

Job description

Role: WeldingProcess Engineer

Location:Cheltenham

Job Type:Permanent

Salary:£46,000 - £48,000

The Process Engineer is responsible for developing, optimising, and maintaining automated mechanical engineering processes and related equipment to ensure consistently high product quality, process capability, efficiency, and compliance with applicable standards. The role focuses on process robustness, continuous improvement and technical support across production and new product introduction (NPI).

Key Responsibilities

Process Development & Optimisation

• Develop, validate, and optimise mechanical engineering processes for production and new product introduction.
• Define and control critical welding parameters (e.g. current, travel speed, wire feed, shielding gas, heat input).
• Establish robust procedures and operating windows to ensure repeatable, high-quality welds.

Technical Documentation & Standards

• Support internal and external audits relating to welding processes and special process controls.

Quality & Problem Solving

• Provide technical support to production to resolve weld quality issues such as porosity, lack of fusion, distortion, or cosmetic defects.
• Lead root cause analysis activities using structured problem-solving tools (e.g. 5 Whys, Fishbone, PFMEA).
• Implement corrective and preventive actions to improve weld quality and reduce scrap and rework.

Automation & Equipment Support

• Specify, commission, and validate automated welding equipment, fixtures, and tooling.
• Work with equipment suppliers and integrators to improve system capability and uptime.
• Support maintenance and calibration strategies for welding equipment and monitoring systems.

Continuous Improvement

• Drive continuous improvement initiatives by applying Lean six-sigma principles focused on productivity, cost reduction, and process capability (Cp/Cpk).
• Support trials of new consumables, materials, and technologies.
• Cross-Functional Collaboration
• Work closely with Design Engineering to influence manufacturability and weld joint design.
• Support Supply Chain and Quality teams with supplier welding capability assessments when required.
• Provide training and technical guidance to operators, technicians, and inspectors.

Requirements

• Strong technical knowledge of mechanical engineering processes
• Proven experience withautomated or robotic welding systems
• Ability to interpret engineering drawings, weld symbols, and specifications.