Manufacturing Engineer Cold Forming

Job Description

Job Description

Benefits:

• 401(k)
• Health insurance
• Parental leave

Manufacturing Engineer Cold Forming
Waco, Texas
Full Time

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. Must have Cold Forming Experience in a manufacturing environment. Experience with steels and aluminum

Responsibilities:
1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. Cross-Functional Leadership
Provide hands-on technical support to operations, maintenance, and quality teams.
Train operators and engineers during launches and process changes.

Qualifications:
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.

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.