Cold Forming Manufacturing Engineer ( Full-time ) Waco, TX - DK

<p><strong>Responsibilities:</strong></p> <p>Machining &amp; Cold Forming Process Engineering</p> <ul type="disc"> <li>Develop, optimize, and validate machining and cold forming processes for high-volume production. </li> <li>Establish process windows using DOE, SPC, and capability studies (Cp/Cpk). </li> <li>Analyze forming loads, material flow, tool wear, and machining performance to improve quality and throughput. </li> <li>Support on-site troubleshooting of production issues at domestic and international manufacturing locations. </li> </ul> <p><strong>Tooling &amp; Equipment:</strong></p> <ul type="disc"> <li>Specify, design, and qualify forming dies, punches, rolls, fixtures, and machining tooling. </li> <li>Lead on-site die verifications/tests, machine acceptance, and production ramp-ups. </li> <li>Work directly with OEMs and tool shops to commission new equipment and debug tooling. </li> <li>Drive tool life improvement and maintenance strategies across multiple facilities.</li> </ul> <p><strong>New Product Introduction (NPI):</strong></p> <ul type="disc"> <li>Support NPI activities across multiple plants, including feasibility reviews and process selection. </li> <li>Lead pilot builds, PPAP/FAI, and production launches on-site.   </li> <li>Ensure manufacturing readiness through standardized processes and documentation.</li> </ul> <p><strong>Quality &amp; Continuous Improvement:</strong></p> <ul type="disc"> <li>Lead root cause analysis and corrective actions for machining and forming defects. </li> <li>Implement Lean and Six Sigma methodologies to reduce scrap, variation, and downtime. </li> <li>Standardize best practices across sites through process documentation and training.</li> </ul> <p><strong>Materials &amp; Supplier Development:</strong></p> <ul type="disc"> <li>Partner with material suppliers on wire, bar, heat treatment, and coatings. </li> <li>Conduct supplier process audits and capability assessments. </li> <li>Support sourcing decisions and cost-reduction initiatives through technical expertise.</li> </ul> <p><strong>Cross-Functional Leadership:</strong></p> <ul type="disc"> <li>Provide hands-on technical support to operations, maintenance, and quality teams. </li> <li>Train operators and engineers during launches and process changes. </li> </ul> <p>Act as a technical liaison between plants, suppliers, and corporate engineering.</p> <p> </p> <p><strong>Qualifications:</strong></p> <ul type="disc"> <li>Bachelor’s degree in manufacturing, mechanical, or industrial engineering (or similar disciplines).  </li> <li>10+ years of experience in machining and/or cold forming environments. </li> <li>Strong understanding of metal forming physics, machining fundamentals, and tooling. </li> <li>Proven experience supporting production in multi-site or supplier-facing roles. </li> <li>Willingness and ability to travel up to 75%, including extended on-site assignments.</li> </ul> <p> </p> <p><strong>Preferred Qualifications:</strong></p> <ul type="disc"> <li>Experience with high-volume cold heading, progressive forming, or precision machining. </li> <li>Knowledge of steels, alloys, heat treatment, and surface coatings. </li> <li>Experience working with global suppliers or international manufacturing plants. </li> <li>Six Sigma Green Belt or equivalent.</li> </ul> <p><strong>Work Environment &amp; Travel:</strong></p> <ul type="disc"> <li>75% travel required to manufacturing plants, tool shops, and supplier locations. </li> <li>Hands-on, shop-floor–focused role with extended time on-site during launches and issue resolution. </li> <li>Remaining time split between home office and engineering documentation.</li> </ul> <br /> Security Clearance Required: No<br /> Visa Candidate Considered: No<br /> <strong>Compensation:</strong><br /> Base Salary - USD $150,000 to $170,000