Process Welding Engineer

Pridgeon & Clay Inc; Grand Rapids (MI); On-site; USD 85,000 - 115,000; Full time

Job summary

Pridgeon & Clay Inc. seeks a Welding Process Engineer to lead a multi-disciplinary team in welding and assembly operations, driving process improvements and program development for robotic welding systems.

You will manage projects, mentor engineers, and collaborate with cross-functional teams to ensure quality, safety, and on-time delivery while advancing lean initiatives and APQP compliance.

Qualifications

• Bachelor's degree in engineering (emphasis in welding).
• At least 1 year of engineering experience in a manufacturing environment including launching new product, 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, with ability to drive projects to completion.
• Experience programming robotic welders (Fanuc, ABB, Panasonic, Motoman, etc)
• Skills to develop consistent weld parameters and processes to control them, with experience using statistical process analysis to ensure process produces 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)
• Computer proficiency in Microsoft Office (including Word, Excel, Project and PowerPoint)
• Understanding of datum structures and blueprints, including ability to apply Geometric Dimensioning and Tolerancing (GD&T) methods to new and old part prints, and ability to interpret Coordinate Measuring Machine (CMM) layout results
• Experience in problem solving methods (8D, 5 Why) and lean initiatives
• Ability and willingness to work in a team-based environment
• Ability and willingness to travel
• Excellent communication and leadership skills
• An excellent work record, including attendance

Responsibilities

• Lead Welding Technicians and Weld Engineering Interns in projects.
• Forecast headcount and recruit/hire team members.
• Improve team communication with regular meetings and status updates.
• Provide feedback and administer disciplinary actions per Employee Handbook.
• Conduct annual performance reviews and document action plans.
• Oversee weld and assembly departments when needed.
• Create/modify Fanuc welding programs; Fronius/ Lincoln equipment programs.
• Maintain welding parameters and Welding Procedure Specifications.
• Troubleshoot to permanent fixes; reduce cycle time.
• Read GD&T and interpret CMM data; ensure quality.
• Participate in 8D/5 Why teams; support safety initiatives.
• Maintain equipment per OSHA/MIOSHA/company standards.
• Plan for cost reductions and lean objectives.
• Communicate plant goals and opportunities; drive 5S and lean.
• Cost reductions and lean cost avoidance reporting.

Skills

Bachelors engineering

Engineering experience

Machine build PM

Robot welding programming

Weld parameters

Statistical process control

Continuous Improvement

APQP

AIAG Core Tools

MS Office

GD&T

CMM interpretation

8D/5 Why

Teamwork

Travel

Leadership

Attendance

Education

Bachelors engineering

Tools

SolidWorks

Minitab

Job description

Are you looking for a challenging yet rewarding job that allows you to utilize your skills to their fullest potential? Do you want to join a team of hardworking, enthusiastic and creative people and enjoy working with a company that recognizes and embraces diversity? Do you take pride working with a company that is committed to being a great corporate citizen and playing a role in producing the highest quality products and services?

If you answered yes to any of these questions, then Pridgeon and Clay is the place for you...

Founded in 1948 by John Pridgeon and Donald Clay, we are one of the largest independent, value-added manufacturers and suppliers of automotive stamped and fine-blanked components in the United States.

Objective: The Welding Process Engineer will interface with the Plant to develop and modify existing and upcoming programs and processes on robotic welding, automatic, and semi-automatic welding systems in an exemplary manner according to the company policies.

Qualified candidates will possess the following Minimum Requirements:

• A Bachelor's Degree in engineering (emphasis in welding)
• A minimum of one year of engineering experience in a manufacturing environment including launching new product, 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, with ability to drive projects to completion
• Experience programming robotic welders (Fanuc, ABB, Panasonic, Motoman, etc)
• Skills to develop consistent weld parameters and processes to control them, with experience using statistical process analysis to ensure process produces 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)
• Computer proficiency in Microsoft Office (including Word, Excel, Project and PowerPoint)
• Understanding of datum structures and blueprints, including ability to apply Geometric Dimensioning and Tolerancing (GD&T) methods to new and old part prints, and ability to interpret Coordinate Measuring Machine (CMM) layout results
• Experience in problem solving methods (8D, 5 Why) and lean initiatives
• Ability and willingness to work in a team-based environment
• Ability and willingness to travel
• Excellent communication and leadership skills
• An excellent work record, including attendance

Outstanding candidates will possess the following Desired Requirements:

• 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

(Minimum requirements are updated annually to meet the demands of various positions; employees hired prior to the latest revision update may not meet all current requirements)

Essential Functions:

Personnel/Workforce Management:

• Manage a multi-disciplinary team consisting of Welding Technicians, Maintenance Technicians, and Weld or Process Engineering Interns while working with engineering leadership throughout the company.
• Participate in future headcount forecasting and propose solutions for fluctuations. Create requisitions, recruit, interview, hire and on-board new team members as needed.
• Lead efforts to enhance team communication, including regular team meetings and status updates. Effectively communicate with co-workers and other management personnel to enhance teamwork and communication initiatives.
• Notify team members of technical and training opportunities to promote development, especially through Career Path program.
• Provide consistent feedback to employees regarding job task performance and accomplishment of goals. Address unacceptable performance by fairly administering disciplinary actions using the Company Employee Handbook.
• Complete and present annual performance reviews for all direct report employees, outlining positive and negative performance, and documenting a plan of action for sub-par performers.
• Oversee weld and assembly departments in absence of a Team Leader or Production Manager.

Leadership & Mentorship:

• Update and maintain the "lessons learned" database with information learned from previous welding and assembly operations.
• Lead other Welding Engineers and process engineering participants in best practices, lessons learned, and process control, on a daily basis.
• Assist the Engineering Manager by leading the Weld Engineers in key projects, as well as the team's daily activities as needed, particularly during the unavailability of the Manager. Provide leadership on project teams, which will include assisting with developing project approval packages, participating in approval review meetings, developing request for quote (RFQ) packages for contractors/vendors, and performing vendor selection.
• Determine necessary manpower and resources required for each project; coordinate with the concerned departments on these requirements to ensure on time delivery and zero disruption to other projects. Establish and implement project plans; ensure staff has the necessary skills and expertise required for the tasks. Evaluate ongoing projects, making recommendations and directs necessary changes in the methods or processes, by utilizing innovation and creativity.
• Provide processing, labor requirements and capital cost to the Cost Estimating department as needed and in a timely manner.
• Practice prudent engineering and effectively apply formal engineering training to increase the overall effectiveness of the Engineering Group and enhance the company's positions within the welding and assembly product lines.

Welding Programming:

• Create and modify complex Fanuc robotic welding programs while consistently maintaining the essential welding parameters. Change as necessary the weld data, torch angels, electrical extension, starting techniques, and other robotic/welding variables.
• Create and modify programs for Fronius and Lincoln welding equipment to produce welds that meet the customer's code/specification stated on the print.
• Create and modify programs for end forming equipment/tooling to produce parts that meet gage or CMM requirements.
• Create and modify programs for leak testing equipment/tooling to produce parts that meet the required leak rates.
• Document and maintain welding parameters on the Welding Procedure Specification.
• Apply troubleshooting knowledge to improve processes and equipment with the goal of achieving permanent fixes.
• Analyze and determine proper weld sequence for cycle time and part dimensional improvements to reduce cycle time and ensure part consistency.

Welding Equipment:

• Using cost justification, accurately and efficiently selects the required components, automation, and controls for machine building/automation. The automation includes, but not limited to: robots, pick & place units and conveyors.
• Assist in wiring, installation, and integration of internally and externally built equipment.
• Complete preventative maintenance per the instructions on weld fixture, weld cells, and auxiliary equipment. Provide suggestions to continuously improve the preventative maintenance schedules.
• Provide assistance in the design, build, installation, and startup of weld cells/fixtures, size machine/tools, leak test machine/tools, and all auxiliary equipment.
• Complete equipment changeovers according to the changeover instructions for weld fixtures, size tools, leak test tools, poke yokes, and all auxiliary equipment.
• Manual weld as needed to support production.

Quality/Safety:

• Read and interpret Geometric Dimension & Tolerancing (GD&T), welding codes/specifications stated on part prints to ensure quality of parts.
• Complete weld cross sectioning by cutting, polishing and etching samples as necessary.
• Analyze gage and Coordinate Measuring Machine (CMM) data to adjust weld fixture details to produce parts that meet dimensional requirements.
• Assist and train operators and welders in determining weld quality using calipers, visual inspection, and destruct tests.
• Participate in 8D and 5-why problem solving teams. Provide assistance to error proofing processes through 8D problem solving.
• Maintain weld equipment and processes to OSHA, MIOSHA, and Pridgeon and Clay standards.
• Identify potential safety issues with processes and systems, and take appropriate action.

Problem-Solving/Continuous Improvement:

• Plan for and achieve departmental achievable goals including customer concerns, cost of quality, cost savings, safety, and on-time Production Part Approval Processes (PPAP's).
• Participate in lean initiatives such as continuous improvement events, and identity and elimination of all types of waste.
• Provide leadership and technical support for 5S and lean objectives.
• Assist the other Process Engineers in data collection for continuous improvement activities.
• Maintain weld equipment and processes to OSHA, MIOSHA, and Pridgeon and Clay standards.
• Communicate thoughts and ideas for the plant goals, problems, and opportunities for improvement to plant operations.
• Compare productivity metrics with quality metrics. Add or remove quality checks to promote a quality process while steadily improving productivity.
• Identify potential safety issues with processes and systems, and take appropriate action.
• Engineer improvements for process setups, material handling, storage, layouts, work cells, and any other functions that directly impact the performance of the plant.
• Accurately calculate and submit cost reductions and cost avoidances using approved guidelines to meet or exceed annual goals.

Professionalism/Communication/Teamwork:

• Consistently exhibit appropriate attendance habits, working the hours necessary to perform the job.
• Organize and maintain efficiency of personal work area.
• Consistently adhere to, and support, company policies and procedures, including ISO, AIAG, IATF 16949 and safety regulations.
• Provide necessary, accurate, and timely feedback of all pertinent information to co-workers and management.
• Effectively communicate with co-workers and management personnel to enhance teamwork and communication initiatives.
• Treat all co-workers with dignity and respect. Exhibit all the attributes of a positive role model (including professionalism, personal integrity, and positive attitude) for employees and managers to emulate.
• Assist in maintaining company values (Integrity, People, Customers, Safety and Ownership) daily, through thoughts and actions.

In return, Pridgeon and Clay will provide:

• A competitive total compensation including a comprehensive benefit plan including premium medical and prescription coverage starting at just $5.00 per week for employee coverage, dental, vision, 401(k) with company match, and tuition reimbursement.
• A safe, team oriented work environment with a leadership team that treats you like family and values your input
• An opportunity to participate in shaping the success of the organization through continuous improvement and problem solving events
• A positive work/life balance
• An opportunity for career growth – Over 70% of our leaders have been promoted from within