Cold Forming Manufacturing Engineer Waco, TX - DK

Responsibilities

Machining & Cold Forming Process Engineering

• Develop, optimize, and validate machining and cold forming processes for high-volume production.
• Establish process windows using DOE, SPC, and capability studies (Cp/Cpk).
• Analyze forming loads, material flow, tool wear, and machining performance to improve quality and throughput.
• Support on-site troubleshooting of production issues at domestic and international manufacturing locations.

• Specify, design, and qualify forming dies, punches, rolls, fixtures, and machining tooling.
• Lead on-site die verifications/tests, machine acceptance, and production ramp‑ups.
• Work directly with OEMs and tool shops to commission new equipment and debug tooling.
• Drive tool life improvement and maintenance strategies across multiple facilities.

• Support NPI activities across multiple plants, including feasibility reviews and process selection.
• Lead pilot builds, PPAP/FAI, and production launches on‑site.
• Ensure manufacturing readiness through standardized processes and documentation.

• Lead root cause analysis and corrective actions for machining and forming defects.
• Implement Lean and Six Sigma methodologies to reduce scrap, variation, and downtime.
• Standardize best practices across sites through process documentation and training.

• Partner with material suppliers on wire, bar, heat treatment, and coatings.
• Conduct supplier process audits and capability assessments.
• Support sourcing decisions and cost‑reduction initiatives through technical expertise.

• Provide hands‑on technical support to operations, maintenance, and quality teams.
• Train operators and engineers during launches and process changes.

Act as a technical liaison between plants, suppliers, and corporate engineering.

• Bachelor’s degree in manufacturing, mechanical, or industrial engineering (or similar disciplines).
• 10+ years of experience in machining and/or cold forming environments.
• Strong understanding of metal forming physics, machining fundamentals, and tooling.
• Proven experience supporting production in multi‑site or supplier‑facing roles.
• Willingness and ability to travel up to 75%, including extended on‑site assignments.

• Experience with high‑volume cold heading, progressive forming, or precision machining.
• Knowledge of steels, alloys, heat treatment, and surface coatings.
• Experience working with global suppliers or international manufacturing plants.
• Six Sigma Green Belt or equivalent.

• 75% travel required to manufacturing plants, tool shops, and supplier locations.
• Hands‑on, shop‑floor–focused role with extended time on‑site during launches and issue resolution.
• Remaining time split between home office and engineering documentation.

Security

Clearance Required:

No

Visa Candidate Considered:
No

Base Salary
-USD $150,000 to $170,000