Engineer III, Manufacturing
Advanced Metals Company (AMCO)
Job Purpose:
Establish and support a dedicated Manufacturing Engineering function for Valve & Wellhead products within Pressure Control, with ownership of complete manufacturing engineering documentation, process engineering, manufacturing methods, CNC programming and tooling, technical issue resolution, and process optimization. Develop and control safe, capable, and cost-effective manufacturing processes across machining, welding, assembly, and testing to ensure compliance with approved drawings, applicable API standards, customer specifications, quality requirements, delivery commitments, and operational objectives.
Key Responsibilities:
Manufacturing engineering documentation: Own the preparation, review, release, and revision control of manufacturing routings, process plans, work instructions, setup sheets, CNC programs, tooling lists, welding requirements, assembly instructions, test procedures, inspection stages, and supporting technical records for Valve & Wellhead products.
Process engineering: Define, develop, validate, and improve manufacturing processes covering machining, welding, assembly, pressure testing, functional testing, and related production activities.
Technical review: Review drawings, bills of materials, specifications, material requirements, tolerances, weld details, quality plans, test requirements, API requirements, and customer specifications to establish compliant manufacturing methods.
Manufacturing methods: Determine operation sequences, work-center requirements, process parameters, inspection and hold points, resource needs, standard times, and acceptance criteria for new and existing products.
CNC, tooling, and fixtures: Develop, verify, optimize, and control CNC milling and turning programs, cutting-tool selections, jigs, fixtures, gauges, work holding, and specialist tooling required for safe and repeatable manufacturing.
Welding and special processes: Coordinate the technical requirements for welding, weld repair, procedure and personnel qualifications, consumable control, traceability, preheat, post-weld heat treatment, NDE, heat treatment, surface treatment, coating, cladding, hardness verification, positive material identification, and other special processes with qualified personnel and Quality.
Assembly and testing: Develop, validate, and improve controlled methods for component identification, cleanliness, dimensional verification, fit-up, torquing, seal and trim installation, lubrication, preservation, hydrostatic testing, gas testing, functional testing, test-equipment setup, test safety, acceptance criteria, recording, and final release in accordance with product, API, and customer requirements.
Industrialization and validation: Lead or support design-for-manufacture reviews, manufacturing feasibility assessments, manufacturing readiness reviews, process risk assessments, process trials, prove-outs, first-article or first-piece activities, capability studies, production handover, and the controlled introduction of new products, equipment, suppliers, or manufacturing methods.
Technical issue resolution: Lead structured investigation of manufacturing, quality, tooling, welding, assembly, and testing issues; identify root causes; implement corrective actions; and escalate design or specification matters to the responsible authority.
Process optimization: Analyze process performance and implement approved improvements to safety, quality, cycle time, capacity, flow, tool life, first-pass yield, cost, scrap, rework, and delivery performance.
Cross-functional and supplier coordination: Coordinate with Product Engineering, Production, Quality, HSE, Maintenance, Supply Chain, Planning, and approved suppliers to confirm manufacturability, technical requirements, supplier capability, process qualification, first-article requirements, outsourced special-process controls, technical deliverables, and resolution of supplier-related manufacturing issues.
Accountabilities:
Manufacturing engineering documentation ownership: Ensure all required manufacturing engineering documentation is complete, approved, current, traceable, and available before work begins, including applicable drawings, bills of materials, routings, process plans, CNC programs, tooling and fixture requirements, welding and special-process requirements, assembly instructions, inspection and test plans, acceptance criteria, hold and witness points, approved deviations, and required manufacturing records.
Process compliance: Ensure machining, welding, assembly, and testing processes comply with approved drawings, procedures, applicable API standards, customer specifications, HSE controls, and quality requirements.
Manufacturing readiness: Confirm process capability, tooling, fixtures, programs, instructions, qualifications, inspection points, and test arrangements are ready for production release.
Technical issue resolution: Provide timely manufacturing-engineering analysis, containment recommendations, root-cause investigation, and corrective-action support for process-related issues. Escalate design changes, material substitutions, repairs, use-as-is dispositions, acceptance-criteria changes, and deviations from API or customer requirements to Product Engineering, Quality, the customer, or another authorized approval authority, as applicable.
Quality, delivery, and process performance: Monitor and improve agreed Manufacturing Engineering indicators, including technical-package release timeliness, first-pass yield, process capability, NCR recurrence, scrap and rework, test failures, cycle-time performance, manufacturing cost, corrective-action closure, and implementation effectiveness against approved departmental targets.
Productivity and cost: Improve cycle time, throughput, tool life, labor utilization, equipment effectiveness, and manufacturing cost through controlled process optimization.
Change and configuration control: Ensure changes to design inputs, process sequences, tooling, CNC programs, materials, welding, special processes, assembly methods, inspection stages, test methods, acceptance criteria, repairs, concessions, and supplier processes are technically assessed, risk reviewed, approved by the authorized functions, validated where required, revision controlled, and communicated before implementation.
Person Specifications:
Minimum qualification: Bachelor’s degree in Mechanical, Manufacturing, Production, or Industrial Engineering; a relevant diploma with suitable manufacturing experience may be considered.
Experience: 0 to 5 years of relevant experience in manufacturing engineering, including practical responsibility for controlled manufacturing processes, technical packages, process validation, and issue resolution in pressure-control, valve, wellhead, oil and gas, or comparable engineered-product manufacturing.
Pressure Control manufacturing: Working knowledge of machining, welding, assembly, pressure testing, functional testing, material traceability, and controlled manufacturing of valves, wellheads, or similar pressure-containing equipment.
Codes and requirements: Working knowledge of applicable API product and quality-management requirements, customer specifications, approved engineering standards, drawings, GD&T, bills of materials, material specifications, inspection and test plans, product specification levels, material traceability, manufacturing records, and document-retention requirements relevant to Valve and Wellhead products.
Process engineering: Ability to develop process flows, routings, work instructions, standard times, process parameters, validation plans, risk controls, inspection stages, and acceptance criteria.
Machining and CNC: Knowledge of CNC turning and milling, cutting tools, fixtures, workholding, cycle-time estimation, and CAD/CAM software such as Edgecam or Mastercam; familiarity with common machine controls is preferred.
Welding, assembly, and testing: Basic knowledge of welding documentation and qualification controls, special processes, controlled assembly, torqueing, cleanliness, preservation, hydrostatic or gas testing, and functional verification.
Problem solving and improvement: Ability to use root-cause analysis, corrective action, process capability, data analysis, Lean methods, and risk-based thinking to resolve issues and optimize processes.
Systems and communication: Proficient in Microsoft 365 and technical recordkeeping, with good written and spoken English and the ability to communicate manufacturing requirements across functions.