Project Engineer - Welding in Telford, Tennessee at ebm-papst Inc.

ebm-papst, Inc.

Job Description

Job Title: Project Engineer – Welding Processes

Position Summary

The Project Engineer is responsible for leading the planning, development, installation, optimization, and continuous improvement of welding processes and equipment within a manufacturing environment. The role supports new product launches, capital equipment projects, automation initiatives, quality improvements, cost reduction efforts, and production capacity expansion. The Project Engineer works closely with Operations, Quality, Maintenance, Tooling, Product Engineering, and outside suppliers to ensure safe, efficient, and repeatable welding processes.

Key Responsibilities

Project Management

• Lead welding-related capital projects from concept through production launch.
• Develop project scopes, budgets, schedules, and resource plans.
• Coordinate equipment procurement, installation, commissioning, and validation.
• Manage contractors, integrators, and equipment suppliers.
• Track project costs, timelines, and deliverables.
• Prepare reports and project status updates for management.

Welding Process Engineering

• Develop and optimize welding processes including:
  • MIG/GMAW
  • TIG/GTAW
  • Resistance Spot Welding
  • Projection Welding
  • Robotic Welding
  • Laser Welding
• Establish welding parameters, process controls, and standard work.
• Design and implement welding fixtures and tooling.
• Improve cycle times, productivity, and equipment utilization.
• Support DFMA (Design for Manufacturability and Assembly) initiatives.

Automation & Robotics

• Support robotic welding cell implementation and optimization.
• Coordinate robot programming and process validation.
• Improve robotic uptime, throughput, and weld quality.
• Evaluate automation opportunities for labor reduction and productivity improvements.
• Lead integration of vision systems, conveyors, and automated material handling systems.

Quality Assurance

• Ensure compliance with applicable welding codes and standards.
• Develop and maintain Welding Procedure Specifications (WPS).
• Support Procedure Qualification Records (PQR) where required.
• Analyze weld defects and implement corrective actions.
• Utilize SPC, PFMEA, Control Plans, and root cause analysis methodologies.
• Lead continuous improvement initiatives to reduce scrap and rework.

Production Support

• Troubleshoot welding process issues.
• Support daily manufacturing operations.
• Provide technical guidance to supervisors, weld technicians, and operators.
• Establish preventive maintenance requirements for welding equipment.
• Drive safety improvements in welding operations.

Continuous Improvement

• Lead Lean Manufacturing and Six Sigma initiatives.
• Reduce welding consumable usage and operating costs.
• Improve Overall Equipment Effectiveness (OEE).
• Develop process capability metrics and performance dashboards.
• Identify opportunities for capacity expansion and throughput improvement.

Qualifications

Education

• Bachelor's Degree in (either):
  • Mechanical Engineering
  • Manufacturing Engineering

Experience

• 5+ years of manufacturing engineering or project engineering experience.
• Experience with automated or robotic welding systems preferred.
• Experience managing capital equipment projects.
• Experience in high-volume manufacturing environments preferred.

Technical Skills

• Welding process development and optimization.
• Robotic welding systems.
• Fixture and tooling design.
• CAD software (SolidWorks, AutoCAD, Inventor, CATIA, or similar).
• Industrial automation systems.
• Root Cause Analysis and problem-solving methodologies.
• APQP, PFMEA, Control Plans, and PPAP.
• Lean Manufacturing and Continuous Improvement principles.

Preferred Certifications

• Certified Welding Inspector (CWI)
• Certified Welding Engineer (CWEng)
• Certified Welding Supervisor (CWS)
• Project Management Professional (PMP)

Key Performance Indicators (KPIs)

• Project completion on schedule and within budget.
• Weld quality and defect reduction.
• Scrap and rework reduction.
• OEE improvement.
• Welding cell throughput increases.
• Labor productivity improvements.
• Equipment uptime and reliability.
• Safety performance metrics.

Physical Requirements

• Frequent presence in manufacturing environments.
• Ability to lift up to 25 lbs.
• Ability to stand and walk for extended periods.
• Ability to wear required PPE including welding PPE when necessary.
• Occasional travel to suppliers and customer locations.

Benefits: Eligible employees receive a comprehensive benefits package including medical, dental and vision insurance; HSA options; life and disability insurance; voluntary supplemental benefits; a 401(k) retirement plan with company contributions; and paid time off.