Engineer - Process Innovation Team

Summary

The Welding Consumables Process Innovation Engineer serves as the organization’s leading authority on process technology, manufacturing methods, and continuous improvement for welding filler metals and consumables. This role drives innovation in consumable production—coatings, fluxes, wire manufacturing, extrusion, baking—while improving consistency, productivity, and product performance.

The Process Innovation Expert works across engineering, R&D, operations, and quality teams to evaluate existing processes, develop new manufacturing capabilities, and implement advanced technologies that enhance safety, reliability, efficiency, and competitive advantage.

Key Duties & Responsibilities

Process Innovation & Technology Development

• Lead development and implementation of new manufacturing technologies for welding electrodes, cored wires, solid wires, SAW wire/flux, and related consumables.
• Identify, evaluate, and scale advanced processes such as automated mixing systems, improved extrusion tooling, thermal treatments, wire drawing enhancements, and other novel ideas.
• Perform process characterization and capability studies to drive data-based improvements.
• Partner with R&D to translate new consumable formulations into robust, scalable production processes.
• Benchmark industry best practices and emerging technologies to maintain market leadership.

Process Optimization & Continuous Improvement

• Analyze production workflows to identify bottlenecks, inefficiencies, and quality risks.
• Develop and implement process control strategies to ensure consistent consumable performance.
• Standardize work instructions, material handling processes, and production procedures to improve repeatability across manufacturing shifts and sites.

Cross-Functional Technical Leadership

• Collaborate with Quality to drive root cause analysis for manufacturing defects and implement corrective actions.
• Support Operations with troubleshooting of electrode coating, cored wire fill and closure, wire drawing, flux agglomeration, baking cycles, and packaging.
• Work with Consumable R&D to refine consumable design parameters for manufacturability and performance.
• Provide technical guidance to maintenance teams on critical equipment, tooling, and process control systems.

Data, Testing, and Validation

• Lead the design and execution of process trials, experiments, and pilot runs.
• Oversee measurement systems used for % coating/% fill, eccentricity, particle size distribution, moisture content, wire chemistry, and flux properties.
• Ensure new processes meet internal specifications, welding performance criteria, and relevant standards (e.g., AWS A5 series, ASME, ISO).

Documentation & Training

• Develop technical documentation including process specifications, SOPs, control plans, and troubleshooting guides.
• Provide leadership and mentorship for innovation culture within the manufacturing teams.
• Train engineers, technicians/technologists, and production personnel on new technologies, process requirements, and best practices.

Required Qualifications

• Bachelor’s degree in Manufacturing Engineering, Electrical Engineering, Chemical Engineering, Mechanical Engineering, Materials Science or related field.
• Level II: 3+ Years of relevant experience, Level III: 5+ years of relevant experience, Level IV: 8+ years of relevant experience, Level V: 11+ years of relevant experience.
• As experience level increases breadth and depth of responsibilities will increase. As level increases, the engineer may lead projects with broader scope and responsibility and will act as a resource for colleagues with less experience. It is also expected that with increased levels the individual will be able to solve more complex problems and be able to work independently with minimal guidance.
  • Selected candidate’s Job Level and Pay Grade will be determined based upon qualifications and experience. 
• Deep understanding of one or more consumable production process(es) (e.g., extrusion, wire drawing, flux mixing and firing, core strip forming).
• Experience with Lean, Six Sigma, DOE, and other structured problem-solving tools.
• Knowledge of welding metallurgy and consumable performance characteristics.
• Strong analytical skills with the ability to drive data driven decisions.

Preferred Qualifications

• Hands-on experience with SMAW electrode, solid wire, cored wire, and/or SAW flux production processes.
• Deep understanding of consumable manufacturing.
• Familiarity with AWS A5 filler metal specifications and relevant industry standards.
• Experience in scaling up new technologies from prototype to full production.
• Strong project management background with the ability to lead cross functional initiatives.