Manufacturing Engineer (Cold Forming)

Job Summary

The Advanced Manufacturing Engineer (Machining & Cold Forming) is responsible for developing, optimizing, and supporting high-volume metal manufacturing processes across multiple manufacturing sites and supplier locations. This role focuses on CNC machining, cold forming, cold heading, rolling, extrusion, and secondary operations. The position requires up to 75% travel to support plant launches, process improvements, tooling validation, and supplier development.

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.

Tooling & Equipment

• 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.

New Product Introduction (NPI)

• 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.

Quality & Continuous Improvement

• 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.

Materials & Supplier Development

• 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.

Cross-Functional Leadership

• 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 50%-75%, including extended on-site assignments.

Preferred Qualifications

• 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.

Work Environment & Travel

• 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.