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:

• Bachelor’s 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-floor–focused role with extended time on-site during launches and issue resolution. 
• Remaining time split between home office and engineering documentation.

Salary : $150,000 - $170,000