Welding Process Engineer (MIG, TIG, Spot)

We are seeking an experienced and innovative Senior Welding Process Engineer to lead welding technology initiatives across MIG, TIG, and Resistance Spot welding applications. This role is pivotal in driving process innovation, enhancing weld quality, optimizing costs, and ensuring compliance with international standards. The ideal candidate will play a strategic role in process development, mentoring engineers, interfacing with design and quality teams, and leading continuous improvement efforts in welding operations.

Key Responsibilities:

1. Process Leadership and Development

• Lead development and implementation of advanced welding processes (MIG, TIG, Spot) for new and existing products.

• Define and validate Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Weld Maps per applicable codes.

• Introduce new welding technologies, automation, and fixtures to improve quality, consistency, and efficiency.

2. Quality Control and Defect Management

• Establish and oversee weld inspection criteria using NDT (UT, RT, PT, VT) techniques.

• Lead root cause analysis (RCA) and corrective actions for welding defects (e.g., lack of fusion, cracking, burn-through).

• Drive process capability improvements (CP, CPK) and ensure adherence to ISO, AWS, ASME, or customer-specific welding standards.

3. Cross-Functional Collaboration

• Collaborate with Design, R&D, Tooling, Quality, and Production teams during product development and process change.

• Support DFM/A (Design for Manufacturing/Assembly) efforts with robust weld solutions.

• Manage vendor relationships for outsourced welding and process qualification.

4. Continuous Improvement and Lean Initiatives

• Lead kaizen events, process audits, and 5S initiatives within the welding function.

• Analyze weld costs and cycle times to recommend cost-saving opportunities.

• Implement digital tools and data analysis for predictive quality and weld monitoring.

5. Mentoring and Team Development

• Guide and mentor junior engineers and welding technicians.

• Deliver technical training on welding standards, safety practices, and equipment usage.

• Promote a culture of quality, safety, and technical excellence in the welding team.

Qualifications:

• Bachelor’s or Master’s degree in Welding Engineering, Mechanical Engineering, or Metallurgy.

• 6+ years of hands-on experience in welding process engineering, including MIG, TIG, and Resistance Spot Welding.

• Proven experience with welding standards: AWS D1.1, ASME Section IX, ISO 3834, or equivalent.

• Strong understanding of metallurgy, weld symbols, thermal effects, and distortion control.

• Proficient in use of welding robots, automated systems, and weld simulation tools is preferred.

• Skilled in quality tools such as FMEA, DOE, Control Plans, and Six Sigma methods.

• Exceptional communication, leadership, and project management skills.

Key Focus Areas:

• Advanced Welding Process Design and Standardization

• Welding Automation, Robotics, and Technology Integration

• Defect Prevention and Quality Assurance

• Mentoring and Team Leadership

• Lean Manufacturing and Process Efficiency

• Strategic Cross-Functional Collaboration

Work Environment:

• Office and production floor; direct exposure to welding operations and automation equipment.

• Required use of PPE in all welding environments.

• Occasional travel to suppliers, customer sites, or other manufacturing facilities.