Welding Engineer

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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.

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Key Responsibilities

• 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).
  
  

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• 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.
  
  

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• Weld Quality & Validation
• Establish weld quality criteria (penetration, bead profile, porosity, spatter limits).
• Define inspection and validation plans:
• Destructive testing (macro-etch, tensile, bend tests)
• 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).
  
  

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• 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.
  
  

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• 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).
  
  

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• 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.
  
  

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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).
  
  

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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).
  
  

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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).
  
  

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Key Performance Indicators (KPIs)

First Pass Yield (FPY) ≥ 98%

Weld defect rate

Cycle time adherence (±5% of target JPH)

CPK ≥ 1.33 (≥1.67 for critical joints)

Reduction in rework and consumable cost

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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.
  
  

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Work Environment

• High-volume automotive manufacturing facility (ladder frame welding lines).
• Hands-on shop floor involvement (50–70% of time during launch phase).