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, and transfer to the operations team.
• Drive continuous improvement in safety, quality, delivery, cost, uptime, scrap, electrode life, energy use, and overall equipment effectiveness. What are the key skills we are looking for?
• Automation Integration — intermediate level; implementing automated solutions to streamline assembly operations
• Influencing Skills — intermediate level; driving alignment across technical and business stakeholders on complex projects
• Lean Methodology — developing level; applying lean principles to eliminate waste and optimize workflows
• Material Flow Design and Methodology — intermediate level; designing efficient material movement systems for production environments
• Product Data Management — intermediate level; managing technical documentation and product specifications throughout project lifecycles
• Quality Control & Inspection — intermediate level; establishing quality standards and inspection protocols for assembly processes
• Change Management — intermediate level; leading teams through technology transitions and process transformations
• Risk Management — developing level; identifying and mitigating risks in industrialization projects What qualifications will make you successful?
• Strong technical problem-solving abilities with a focus on practical, scalable solutions
• Proven ability to coach and guide junior engineers while fostering collaborative team environments
• Excellent communication skills to translate complex technical concepts for diverse audiences
• Results-driven mindset with the ability to manage multiple priorities independently What's in it for me?
• Be recognized as a global technical expert with real influence on manufacturing strategy
• Work on transformative projects that directly impact production efficiency and innovation
• Collaborative culture that values technical excellence and continuous improvement
• Growth opportunities to expand your expertise and advance your engineering career Requirements
• Bachelor’s degree in Welding Engineering, Materials Engineering, Mechanical Engineering, Electrical Engineering, Mechatronics, Manufacturing Engineering, or a related technical field.
• Five or more years of manufacturing engineering experience supporting resistance welding or comparable joining processes in a production environment.
• Hands-on experience developing and troubleshooting resistance spot or projection welding processes for high-volume manufacturing.
• Experience with new product industrialization, equipment specification, supplier management, process validation, and production launch.
• Working knowledge of metallurgy, material properties, coatings, heat generation, current flow, electrode wear, and joint design as applied to resistance welding.
• Experience applying Lean Manufacturing and Six Sigma methods, including 5S, value-stream mapping, Kaizen, mistake-proofing, and structured problem solving.
• Demonstrated continuous-improvement results affecting safety, quality, delivery, cost, labor efficiency, equipment reliability, or launch performance. TECHNICAL
• Resistance welding process development and optimization
• Knowledge of welding controls, transformers, secondary circuits, shunts, tooling, electrodes, water-cooling systems, and weld monitoring.
• Ability to interpret weld signatures and process data, including current, voltage, resistance, force, displacement, and energy trends.
• Experience with weld-quality testing, metallographic sample preparation, cross-section analysis, and measurement of nugget or fusion characteristics.
• Proficiency with PFMEA, control plans, Gage R&R, MSA, SPC, capability analysis, DOE, and root-cause analysis.
• AutoCAD and Creo, Pro/E, or SolidWorks.
• Basic understanding of PLC programming, robotic welding cells, safety circuits, industrial networks, MES/MIS systems, and production traceability.
• Familiarity with vision systems, sensors, servo actuators, pneumatic systems, and automated material handling.
• Proficiency with Microsoft Office tools; familiarity with SAP and production modeling or simulation software is preferred.
• Knowledge of applicable resistance welding standards and internal safety, quality, and equipment requirements. TRAVEL
• Travel required up to 30%, domestic and international, based on project assignment. CRITICAL BEHAVIORS
• Works effectively within multidisciplinary and multicultural project teams, including Product Design, Quality, Purchasing, Industrialization, Automation, Maintenance, Suppliers, and Operations.
• Demonstrates a hands-on, data-driven approach to troubleshooting and process optimization.
• Performs structured root-cause analysis and develops clear action plans that eliminate technical and operational barriers.
• Communicates technical information clearly in English, both written and verbal, for shop-floor, supplier, and leadership audiences.
• Influences technical decisions through evidence, risk assessment, cost analysis, and effective negotiation.
• Takes ownership, manages multiple projects in parallel, and works effectively with minimal supervision.
• Prioritizes safety, product quality, process discipline, and knowledge transfer throughout equipment development and launch. Preferred Qualifications
• Experience with copper, plated copper, steel, stainless steel, nickel, aluminum, or dissimilar-material welding applications.
• Experience with automated electrode dressing, weld-current monitoring, adaptive control, force monitoring, displacement monitoring, or real-time process analytics.
• Professional certification or formal training in resistance welding, welding engineering, materials science, or Six Sigma.
• Experience in electrical products, circuit protection, electromechanical devices, or similarly regulated high-volume manufacturing. Bring your technical leadership to a team that's building the future — apply today Rewards designed for you Our Total Rewards is our way of saying: We see you and we value you. It’s more than just pay and benefits—it’s a meaningful investment in you. It is designed to help you perform, grow, feel safe, and elevate your potential. The package helps you care for yourself and your family, plan your future, grow your skills and career, collaborate in an inclusive workplace, and contribute to your community. At Schneider Electric, we’re here for what matters most to you. Discover more at our Career Page.
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