Senior Thread Roll Engineer

We are seeking a Senior Thread Roll Manufacturing Engineer to serve as the company’s primary technical authority for thread‑forming processes across our aerospace fastener product lines. This role is ideal for a seasoned engineer with deep hands‑on experience in Reed thread‑rolling machines, cylindrical dies, flat dies, and fillet‑roll operations.

You will lead the modernization, optimization, and troubleshooting of all thread‑rolling operations, ensuring world‑class capability, repeatability, and throughput. As a senior technical resource, you will mentor engineers and operators, drive process innovation, and support New Product Introduction (NPI) with advanced thread‑forming expertise.

This is a high‑impact role that directly influences product quality, mechanical performance, and manufacturing efficiency for critical aerospace and defense hardware.

Key Responsibilities

1. Thread‑Rolling Process Ownership

a. Serve as the subject‑matter expert for all thread‑forming processes, including:

b. Reed two‑die cylindrical thread‑rolling machines

c. Fillet‑roll operations for under‑head radii

d. Flat‑die thread rolling

e. Specialized rolling for high‑strength alloys (MP35N, MP159, A286, Inconel)

f. Develop, validate, and optimize rolling parameters, die geometries, and setups to achieve maximum tool life and process capability.

2. Process Optimization & Continuous Improvement

a. Lead Six Sigma, SPC, and Lean initiatives specifically targeting thread‑roll throughput, scrap reduction, and die‑life improvement.

b. Implement advanced process controls, including capability studies, load‑monitoring systems, and in‑process inspection strategies.

c. Introduce new technologies, automation concepts, and modern Reed machine upgrades.

3. NPI & Engineering Support

a. Partner with NPI engineering to define thread‑forming strategies for new fastener designs.

b. Review customer drawings for manufacturability, GD&T compliance, and thread‑form feasibility.

c. Create and maintain detailed MPIs, setup sheets, and tooling specifications for all thread‑rolling operations.

4. Shop‑Floor Leadership

a. Provide high‑level troubleshooting support for operators and supervisors.

b. Lead MRB investigations related to thread geometry, surface finish, fillet‑roll defects, and mechanical property failures.

c. Train operators and junior engineers on best practices, die handling, and machine setup.

5. Tooling & Die Engineering

a. Design and specify thread‑rolling dies, fillet‑roll dies, and supporting tooling.

b. Collaborate with die vendors to refine die geometry, coatings, and heat‑treat specifications.

c. Manage die‑life tracking, failure analysis, and continuous improvement cycles.

Required Qualifications

1. Bachelor's degree in mechanical, Manufacturing, or Industrial Engineering. In lieu of a degree, candidates with 15 years of aerospace fastener or precision‑manufacturing experience will be considered, provided they currently hold, and can demonstrate, an engineering level role by trade.

2. Minimum 7 years of hands‑on experience in aerospace fastener thread‑rolling, including Reed machines and fillet‑roll operations.

3. Strong understanding of:

a. GD&T and aerospace blueprint interpretation

b. Thread‑form geometry (UNJ, MJ, UNR, custom forms)

c. Mechanical properties and cold‑working effects

d. Precision metrology (optical comparators, thread gages, profilometers)

4. Experience with CNC machining, forging, and heat‑treat interactions with thread‑forming.

5. Proficiency with SolidWorks or CATIA for modeling and tooling design.

6. Familiarity with ERP/MRP systems (Syteline preferred).

7. Demonstrated success leading process improvement initiatives.

Preferred Experience

1. Expertise with high‑strength alloys such as MP35N, MP159, Wasp Aloy, Armet and Inconel.

2. Prior leadership of a thread‑roll department, engineering group or high‑precision forming cell.

3. Experience integrating automation or digital monitoring into legacy Reed machines.

4. Strong background in die‑failure analysis and die‑life extension strategies.

Compliance & Physical Requirements

1. Must be a U.S. Person (U.S. Citizen or Permanent Resident) per ITAR regulations.

2. Ability to work in both office and shop‑floor environments; occasional lifting of 10–20 lbs.; ability to stand for extended periods.