Job Description
Summary/Objective
The Welding Engineer provides technical expertise to the mill operations in the area of welding process technology and process control. This position also identifies opportunities for improvement of the appropriate welding process, improving efficiency, mill productivity and weld quality. They work extensively with the production, maintenance and quality control management teams to ensure that new and improved best practices are defined, developed and institutionalized across all shifts. They also remain current with new welding technologies and work with vendors and outside welding groups to look for new welding methods, equipment and controls.
Essential Functions
Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
- Provides the necessary guidance, coaching and mentorship for the Welding Technicians and Process Engineer(s).
- Develops and implements best practices for welding set-up and welding process controls for reducing defects and increased quality of welding.
- Develops and implements a training program for SAW, GMAW and SMAW welding techniques and procedures for the operators and welding technicians.
- In collaboration with Operations and QA, approves the WPS / weld parameters for the SAW welding processes.
- Determines the key process control parameters for the applicable type of welding technologies (SAW and GMAW).
- Develops the WPS/PQR and SWCCD documents for both straight seam and girth welding on an order-by-order basis.
- Establishes a database of KPI measurements including a welding KPI report that can be communicated on a shift-by- shift basis to each welding team within the mill.
- Maintains and expands as necessary the weld database (process parameters vs weld quality properties).
- Monitors the set up / programming and adjustment of the welding machines and related equipment.
- Monitors performance metrics, such as SAW downtime and weld defect rate.
- Recommends changes to the weld assembly, processing, tooling and equipment to improve safety, quality, reliability, and productivity of welding processes and cost.
- Oversees the development of a troubleshooting guide for welding set-up problems and weld defects.
- Participates in the development and implementation of the training program for maintenance technicians in the troubleshooting and repair of SAW welding equipment.
- Champions the evaluation and trials of new suppliers / consumables.
- Stays current with new welding technologies and working with vendors and outside welding groups to look for new welding methods, etc.
- Provide assistance for troubleshooting welding quality issues to solve problems while documenting solutions provided and their results.
Skills and Abilities
- Able to identify complex problems and review related information to develop and evaluate options and implement solutions.
- Able to determine how a system should work and how changes in conditions, operations, and the environment will affect outcomes.
- Able to identify measures or indicators of system performance and the actions needed to improve or correct performance, relative to the goals of the system.
- Demonstrate good judgement and decision making by considering the relative costs and benefits of potential actions to choose the most appropriate one.
- Understand the implications of new information for both current and future problem solving and decision-making.
Supervisory Responsibility
This position requires no supervisory responsibility.
Work Environment
While performing the duties of this job, the employee is frequently exposed to fumes, airborne particles, moving mechanical parts and vibration on the production floor. The employee is occasionally exposed to a variety of extreme conditions. The noise level in the work environment can be loud. This position works in an environment in which safety may demand constant attention; and requires safety equipment such as hardhats, safety glasses, earplugs and steel toe shoes.
Physical Demands
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job.
While performing the duties of this job, the employee is regularly required to talk or hear, sit, stand and walk; and occasionally required to stoop, kneel, crouch, climb or balance. The employee may occasionally lift office products and supplies up to 10 pounds. Specific vision abilities required by this job include close vision, distance vision and depth perception
Position Type/Expected Hours of Work
This position is full-time. Standard days and hours of work are Monday through Friday with the schedule determined by the supervisor. Additional hours may be required for special projects or deadlines.
Travel
None is expected for this position.
Knowledge Required
- Knowledge of design techniques, tools and principals involved in production of precision technical plans, blueprints, drawings and models.
- Knowledge of practical application of engineering science and technology. This includes applying principles, techniques, procedures and equipment to the design and production of various goods and services.
- Knowledge of machines and tools, including their designs, uses, repair and maintenance.
- Knowledge of raw materials, productions processes, quality control, costs and other techniques maximizing the effective manufacture and distribution of goods.
- Knowledge of principles and methods for curriculum and training design, teaching and instruction for individuals and groups.
- Knowledge of electronic equipment, and computer hardware and software, including applications and programming. Proficient in computers, including Microsoft Office (Outlook, Word, Excel, PowerPoint).
Required Education and Work Experience
- 2+ years working experience involving welding in a steel manufacturing-related business.
- Thorough knowledge of codes, specifications and standards commonly used in welding of pipe products (AWS D1.1 and 1.5, ASME IX, API 5L, API 1104)
- Working knowledge of problem-solving methods and statistical analysis to achieve improvements to KPI's.
- Experience giving presentations to management regarding project results.
- Experience writing technical reports summarizing key findings and identifying next steps.
- Able to communicate effectively in public speaking situations to relate complex topics to all levels of employees and staff.
- Able to work effectively with hourly and management ranks to solve problems and to challenge the status quo.
- Proficient with Microsoft Office tools such as Word, Excel, and PowerPoint.
Preferred Education and Work Experience
- Metallurgical, Materials or Welding Engineering degree.
- Experience using Minitab and other statistical software.
- Lean Manufacturing and Six Sigma training/experience.
- AWS, Certified Welding Inspector.
- International Welding Engineer certification. (IWE)
