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Cold Forming Manufacturing Engineer_Waco, TX_Full-Time(FTE)_Direct Hire

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Position Title: Cold Forming Manufacturing Engineer
Job Type: Full-Time
Location: Waco, TX
Base Salary: $150,000 to $170,000 + Best-in-class benefits
Industry: Aerospace / Aviation / Defense
Job Category: Engineering - Industrial / Manufacturing

Job Description:
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.

Compensation:
*Full-time
*Benefits - Full
*Relocation Assistance Available - Possible for ideal candidate
*Bonus Eligible - Yes
*Interview Travel Reimbursed - Yes

Candidate Details:
*10+ to 15 years experience
*Seniority Level - Mid-Senior
*Minimum Education - Bachelor's Degree
*Willingness to Travel - Often

Ideal Candidate:
*Must have Cold Forming Experience in a manufacturing environment. 
*Experience with steels and aluminum
*Travel 50% - 75% of time
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Screening Questions:

# Total experience:
# How many years of hands-on experience do you have with Cold Forming, Cold Heading, or Cold Forging manufacturing processes?
# How many years of experience do you have supporting CNC machining operations (turning, milling, grinding) in a high-volume manufacturing environment?
# How many years of experience do you have designing, validating, troubleshooting, or improving forming dies, punches, rolls, fixtures, and machining tooling?
# How many years of experience do you have using DOE, SPC, Cp/Cpk studies, Lean Manufacturing, or Six Sigma methodologies to improve manufacturing processes?
# How many years of experience do you have working with steel and aluminum materials, heat treatment, coatings, and supplier process audits/development?
# What is the reason for seeking change from your current role?
# What is your annual base salary expectations (USD)?
# Are you open for Waco, TX (Onsite):
# Current Location, State with zip code:
# Are you authorized to work in the USA without sponsorship?
# Work authorization for working in USA (USC / GC):