Senior Resistance Welding Process Engineer

We are seeking a motivated Senior Resistance Welding Process Engineer to lead the development, industrialization, qualification, and continuous improvement of resistance welding processes for new product introduction and high-volume manufacturing.

The role will define robust welding methods, equipment, tooling, controls, and validation plans while partnering with Product Design, Quality, Maintenance, Automation, Suppliers, and Operations.

The position reports to the Assembly Chapter Leader.

What will you do?



* Partner with Product Design during product development to drive Design for Manufacturing and Assembly (DFMA), with emphasis on joint geometry, electrode access, material stack-up, coatings, tolerances, and weldability.



* Select and optimize resistance welding technologies, including spot, projection, seam, and cross-wire welding, based on product requirements, materials, throughput, quality, and total cost.



* Develop welding process windows and define critical parameters such as weld current, weld time, electrode force, squeeze and hold time, pulse schedules, and cooling requirements.



* Lead feasibility studies, weld trials, design of experiments, and capability evaluations to establish repeatable and robust processes.



* Define acceptance criteria and validation methods using destructive and nondestructive evaluation, including peel, chisel, tensile, cross-section, nugget measurement, visual inspection, and electrical resistance testing as applicable.



* Develop process FMEAs, control plans, work instructions, reaction plans, and standardized settings.

Apply statistical process control and capability analysis to monitor critical-to-quality characteristics.



* Specify welding machines, power supplies, transformers, weld controllers, electrodes, tooling, fixtures, chillers, fume extraction, safety guarding, and data collection requirements.



* Design and validate electrode materials, profiles, alignment features, dressing methods, replacement criteria, and preventive-maintenance standards to control wear and weld consistency.



* Prepare equipment specifications, requests for quotation, qualification plans, and acceptance criteria.

Lead supplier technical reviews, design reviews, factory acceptance testing, and site acceptance testing.



* Integrate welding equipment into manual, semi-automated, and fully automated assembly systems, including PLC, robot, safety, traceability, and manufacturing execution system interfaces.



* Lead root-cause analysis for weld defects such as expulsion, insufficient nugget, burn-through, cracking, sticking, indentation, misalignment, and unstable resistance signatures.

Implement sustainable corrective actions.



* Create capacity, cycle-time, line-balancing, labor, and return-on-investment analyses for proposed welding solutions.



* Support equipment installation, process qualification, operator and technician training, production ramp-up, ...