Manufacturing Engineer (Cold Forming)

Overview

In this role you will develop, optimize, and support high-volume metal manufacturing processes across multiple sites and supplier locations. You will focus on CNC machining, cold forming, cold heading, rolling, extrusion, and secondary operations to drive capability and throughput. You work with cross-functional teams on plant launches, process improvements, tooling validation, and supplier development, with significant travel. Your impact spans NPI readiness, tooling strategy, and quality improvements that scale across the enterprise.

Responsibilities

• 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 locations
• 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 with OEMs and tool shops to commission new equipment and debug tooling
• Drive tool life improvement and maintenance strategies across facilities
• Lead NPI activities including feasibility reviews, process selection, pilot builds, PPAP/FAI, and production launches
• Ensure manufacturing readiness through standardized processes and documentation
• Lead root cause analysis and corrective actions for machining and forming defects
• Implement Lean and Six Sigma to reduce scrap, variation, and downtime
• Standardize best practices across sites via process documentation and training
• 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
• 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

Key requirements

• 10+ years of experience in machining and/or cold forming environments
• Strong understanding of metal forming physics, machining fundamentals, and tooling
• Willingness to travel 50%-75% (including extended on-site assignments)
• Experience supporting production in multi-site or supplier-facing roles
• Bachelor's degree in manufacturing, mechanical, or industrial engineering (or similar)
• Preferred: experience with high-volume cold heading, progressive forming, or precision machining
• Knowledge of steels, alloys, heat treatment, and surface coatings
• Experience with global suppliers or international manufacturing plants
• Six Sigma Green Belt or equivalent

• cross-functional collaboration
• problem-solving
• training and coaching
• CNC machining
• cold forming
• cold heading