Cold Forming Manufacturing Engineer ( Full-time ) 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.

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.

Qualifications:

• Bachelors 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.

Work Environment & Travel:

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