Welding Engineer

Position Summary The MIG Welding Specialist Engineer is responsible for the development, validation, optimization, and continuous improvement of MIG welding processes for high-volume ladder frame production. This role ensures robust weld quality, cycle time adherence (~25-30 JPH), and compliance with structural, durability, and corrosion requirements while supporting launch (VFF/MRD/PPAP) and steady-state production. ________________________________________ Key Responsibilities 1. Welding Process Development & Industrialization Define and industrialize MIG welding processes for ladder frame assemblies (rails, cross members, brackets). Develop weld schedules (current, voltage, wire feed speed, travel speed, shielding gas mix). Lead weld feasibility reviews during product design (DFM/DFA for weldability, access, distortion control). Establish welding standards aligned with OEM specifications (AWS, ISO, internal specs). ________________________________________ 2. Equipment & Automation Integration Work closely with integrators for welding line design and FAT/SAT validation. Define requirements for robotic MIG welding cells (fixtures, clamps, torch access, reach studies). Support robot programming (Fanuc/ABB/KUKA) including path optimization and cycle time balancing. Validate tooling, fixtures, and clamping strategies to control part variation and distortion. ________________________________________ 3. Weld Quality & Validation Establish weld quality criteria (penetration, bead profile, porosity, spatter limits).

Define inspection and validation plans:

o Destructive testing (macro-etch, tensile, bend tests) o Non-destructive testing (visual, ultrasonic where required) Lead PPAP documentation for welded assemblies (PFMEA, Control Plan, MSA). Ensure compliance with standards such as American Welding Society (AWS

D1.1/D14.3

). ________________________________________ 4. Production Support & Continuous Improvement Monitor welding

KPIs:

first-pass yield (FPY), rework rate, uptime, cycle time. Troubleshoot welding defects (burn-through, lack of fusion, distortion, spatter). Drive root cause analysis using structured methods (8D, 5-Why, Ishikawa). Optimize consumables (wire, gas) and reduce cost per weld. ________________________________________ 5. Launch & Program Execution Support prototype builds (MRD0, VFF1, VFF2) and ensure weld process readiness. Coordinate with stamping, fixturing, and dimensional teams to ensure weld stack-up robustness. Validate weld performance under durability and corrosion conditions (e.g., SAE J2334 exposure). Ensure readiness for SOP with stable CPK targets (>1.33 / >1.67 critical features). ________________________________________ 6. Safety & Compliance Ensure compliance with welding safety standards (fume extraction, PPE, arc flash). Drive implementation of ergonomic and safe welding processes in automated/manual stations. ________________________________________ Required Qualifications Bachelor s degree in Welding Engineering, Mechanical Engineering, or related field. 5-10+ years of experience in MIG welding in automotive structures (BIW or ladder frames preferred). Strong knowledge of robotic welding systems (Fanuc, ABB, KUKA). Expertise in welding of HSLA steels and structural components. Experience with welding standards (AWS, ISO, OEM-specific). ________________________________________ Preferred Qualifications Certified Welding Engineer (CWE) or equivalent certification from American Welding Society. Experience with ladder frame or chassis systems in high-volume production. Familiarity with weld simulation tools (e.g., Simufact Welding, SYSWELD). Experience working in Tier-1 automotive environments (e.g., Magna International-like operations). ________________________________________ Key Technical Skills MIG welding process optimization (GMAW, pulse MIG, tandem MIG). Weld distortion control and fixturing strategy. Robotic path programming and cycle time optimization. Weld inspection and metallurgical evaluation. SPC/CPK and quality systems (PFMEA, Control Plans). ________________________________________ Key Performance Indicators (KPIs) First Pass Yield (FPY) ≥ 98% Weld defect rate < 1% Cycle time adherence (±5% of target JPH) CPK ≥ 1.33 (≥1.67 for critical joints) Reduction in rework and consumable cost ________________________________________ Leadership & Collaboration Interface with product engineering, quality, manufacturing, and suppliers. Lead cross-functional problem-solving teams during launch and production. Provide technical guidance to weld technicians and operators. ________________________________________ Work Environment High-volume automotive manufacturing facility (ladder frame welding lines). Hands-on shop floor involvement (50-70% of time during launch phase).