Spring Coiling, Engineering Technician-1

Flex; Libertyville (IL); On-site; USD 65,000 - 95,000; Full time

Job summary

Flex is seeking an experienced Engineering Technician to support high-volume medical device spring production using WAFIOS equipment in Libertyville, IL. The role covers machine setup, troubleshooting, and continuous improvement across engineering, quality, maintenance, and production teams.

You will analyze spring performance, participate in DOE and CAPA, and train operators on setup, operation, and inspection processes to ensure product quality and process efficiency.

Qualifications

• 8+ years of experience in spring manufacturing, precision manufacturing, or automated production equipment.
• Hands-on with WAFIOS spring coiling machines (FUL, FMU, or equivalent).
• Strong understanding of spring parameters: free length, outside diameter, pitch, spring rate, load testing.
• Experience troubleshooting CNC spring coiling equipment and related automation systems.
• Ability to read and interpret engineering drawings, blueprints, specifications, and tooling designs.
• Experience with preventive maintenance and equipment reliability programs.
• Familiarity with FDA-regulated, medical device or highly regulated manufacturing environments.
• Proficiency with PC-controlled manufacturing equipment and machine interfaces.

Responsibilities

• Set up, adjust, operate, and troubleshoot WAFIOS CNC spring coiling machines including tooling, guides, coiling points, pitch tools, and cutoff systems.
• Support production of compression, extension, and torsion springs used in medical device applications.
• Analyze spring characteristics such as free length, OD, pitch, spring rate, squareness, and load requirements.
• Diagnose and resolve manufacturing issues related to spring geometry, machine setup, tooling wear, material variation, and equipment performance.
• Perform first-piece inspections and process verifications using calipers, micrometers, optical measurement systems, force testers, and spring load testers.
• Investigate process deviations and implement corrective actions to improve quality and efficiency.
• Conduct engineering trials, DOE activities, and capability evaluations.
• Collaborate with engineers to optimize designs, methods, tooling concepts, and settings.
• Support process validation (IQ/OQ/PQ) and CAPA investigations.
• Develop and document machine setup standards and troubleshooting guides.
• Perform preventive maintenance and replacement of worn components.
• Train operators and technicians on setup, operation, inspection procedures.
• Assist with startup, qualification, and commissioning of new equipment.

Skills

Spring manufacturing

CNC troubleshooting

Mechanical aptitude

Root cause analysis

SPC

Process validation

Training & mentoring

Continuous improvement

Tools

WAFIOS machines (FUL/FM U) programming

Spring coiling tooling & adjustments

Electrical troubleshooting (motors, sensors, fuses)

Pneumatic systems

PC-controlled equipment & interfaces

Job description

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world. A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment.

Engineering Technician – Spring Manufacturing & WAFIOS Equipment

Position Summary

We are seeking an experienced Engineering Technician to support the production, setup, troubleshooting, and continuous improvement of CNC spring manufacturing processes. This role is responsible for supporting high-volume medical device spring production using WAFIOS spring coiling equipment and associated secondary operations. The Engineering Technician will work closely with Engineering, Quality, Maintenance, and Production teams to optimize processes, improve equipment performance, troubleshoot manufacturing issues, and support operator training.

Location: Libertyville, IL

Shift Schedule: 0800a-0430p M-F

What a Typical Day Looks Like

• Set up, adjust, operate, and troubleshoot WAFIOS CNC spring coiling machines including tooling, guides, coiling points, pitch tools, and cutoff systems.
• Support production of compression, extension, and torsion springs used in medical device applications.
• Analyze spring characteristics such as free length, outside diameter, pitch, spring rate, squareness, and load requirements.
• Diagnose and resolve manufacturing issues related to spring geometry, machine setup, tooling wear, material variation, and equipment performance.
• Perform first-piece inspections and process verifications using calipers, micrometers, optical measurement systems, force testers, and spring load testers.
• Investigate process deviations and implement corrective actions to improve product quality and manufacturing efficiency.
• Conduct engineering trials, machine studies, DOE activities, and capability evaluations.
• Collaborate with engineers to optimize spring designs, manufacturing methods, tooling concepts, and machine settings.
• Support process validation activities, including IQ/OQ/PQ and process capability studies.
• Develop and document machine setup standards, troubleshooting guides, and best practices.
• Perform preventive maintenance and replacement of worn machine components.
• Troubleshoot mechanical, electrical, pneumatic, and servo-controlled machine systems.
• Analyze production data and equipment performance trends to identify opportunities for continuous improvement.
• Assist with startup, qualification, and commissioning of new spring manufacturing equipment.
• Train operators, spring makers, and technicians on machine setup, operation, troubleshooting, and inspection procedures.
• Support root cause investigations and implementation of corrective and preventive actions (CAPA).

Required Qualifications

• 8+ years of experience in spring manufacturing, precision manufacturing, or automated production equipment.
• Hands-on experience with WAFIOS spring coiling machines (FUL, FMU, or equivalent models preferred).
• Strong understanding of spring manufacturing principles, including:
• Free length
• Outside diameter (OD)
• Pitch
• Spring rate
• Load testing
• Helix and cast
• Material behavior
• Experience troubleshooting CNC spring coiling equipment and related automation systems.
• Ability to interpret engineering drawings, blueprints, specifications, and tooling designs.
• Strong mechanical aptitude and machine setup experience.
• Knowledge of precision measurement equipment and statistical process control methods.
• Experience with preventive maintenance and equipment reliability programs.
• Familiarity with FDA-regulated, medical device, or highly regulated manufacturing environments.
• Proficiency with PC-controlled manufacturing equipment and machine interfaces.

Technical Skills

• WAFIOS machine programming and setup
• Spring tooling adjustments and optimization
• Mechanical troubleshooting
• Electrical troubleshooting including:
• Motor overloads
• Sensors
• Fuses
• Broken wires
• Fault diagnosis
• Pneumatic systems
• Root cause analysis
• Statistical process control (SPC)
• Process validation
• Technical training and mentoring
• Continuous improvement methodologies

Flex is an Equal Opportunity Employer and employment selection decisions are based on merit, qualifications, and abilities. We do not discriminate based on: age, race, religion, color, sex, national origin, marital status, sexual orientation, gender identity, veteran status, disability, pregnancy status, or any other status protected by law. We're happy to provide reasonable accommodations to those with a disability for assistance in the application process. Please email [e-mail] and we'll discuss your specific situation and next steps (NOTE: this email does not accept or consider resumes or applications. This is only for disability assistance. To be considered for a position at Flex, you must complete the application process first).