Senior Process Engineer

Job Description

The Materials & Weld Process Engineer develops, optimizes, and oversees fabrication, welding, and finishing processes within a dynamic manufacturing environment. This role combines hands-on technical work with process engineering, metallurgy, and continuous improvement to ensure high-quality, cost-effective production. The engineer collaborates closely with cross-functional teams, troubleshoots complex welding issues, and leads initiatives that improve product quality, manufacturability, and operational performance while providing technical leadership and mentorship across the organization.

Responsibilities

+ Develop, evaluate, and improve fabrication, welding, and finishing processes to enhance quality, efficiency, and cost-effectiveness.

+ Define sheet metal fabrication parameters, procedures, and specifications for a variety of materials and applications.

+ Define welding parameters, procedures, and specifications for multiple materials and applications across different welding processes.

+ Troubleshoot fabrication and welding defects, perform root cause analysis, and implement effective corrective and preventive actions.

+ Work closely with design and manufacturing teams to ensure the weldability and manufacturability of components throughout the product lifecycle.

+ Evaluate, recommend, and support fabrication and welding suppliers to ensure products meet required technical and quality standards.

+ Define and train teams on welding process validation methods, including destructive and non-destructive testing (NDT).

+ Ensure compliance with applicable industry standards and company quality requirements in all welding and fabrication activities.

+ Train and mentor production staff on best practices in fabrication, welding, and process controls to build organizational capability.

+ Maintain and update documentation such as work instructions, weld maps, and process control plans to support consistent and repeatable production.

+ Collaborate with cross-functional teams to drive manufacturing process improvements and support continuous improvement initiatives.

+ Perform other related duties as assigned to support engineering, production, and quality objectives.

Essential Skills

+ Proven expertise in welding process engineering, including defining, validating, and optimizing welding parameters across TIG, MIG, resistance, and related processes in production environments.

+ Hands-on proficiency in stainless steel TIG welding, including defect analysis, parameter tuning, and quality assurance.

+ Advanced knowledge of sheet metal fabrication processes such as laser cutting, waterjet cutting, bending, and forming with a focus on manufacturability.

+ Demonstrated ability to analyze fabrication and welding processes, perform root cause analysis, and implement corrective and preventive actions for process improvement.

+ Working knowledge of relevant welding, fabrication, and quality system standards and their application in manufacturing.

+ Bachelor's degree in Welding Engineering, Mechanical Engineering, or a related field, or equivalent work experience.

+ At least 8 years of experience in sheet metal and welding engineering, process development, or manufacturing.

+ Proficiency in various sheet metal fabrication processes including waterjet cutting, laser cutting, bending, and forming.

+ Proficiency in multiple welding processes such as MIG, TIG, Stick, Resistance, and Laser welding, with demonstrated strength in stainless steel TIG.

+ Knowledge of metallurgy, heat treatment, and material science as applied to welding and fabrication.

+ Familiarity with CAD software, welding simulation tools, and quality inspection techniques.

+ Strong analytical and problem-solving skills combined with a practical, hands-on approach.

+ Excellent communication and teamwork skills to collaborate effectively with engineering, production, quality, and suppliers.

Additional

Skills & Qualifications

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Experience with robotic and automated welding systems.

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Experience with continuous improvement initiatives in manufacturing environments.

+ Experience performing or overseeing NDT inspection as part of welding process validation.

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