Roll Form Process Engineer

Job Summary: The Process Engineer – Roll Form will be primarily responsible for providing hands-on mechanical engineering support for roll-forming equipment, tooling and manufacturing processes. This role develops and implements engineered solutions that improve equipment reliability, throughput, safety and product quality.

The Process Engineer – Roll Form partners with Operations, Maintenance, Quality, and suppliers to solve complex equipment problems and manage improvements from initial concept through installation, and sustained production.

Job Responsibilities

• Develop and implement mechanical improvements for roll-forming lines, coil-handling equipment, straighteners, presses, and cut-off systems.
• Create or review mechanical designs, equipment layouts, fabrication drawings, tooling concepts and installation packages.
• Apply engineering principles involving force, torque, power transmission, loading, alignment, tolerance and component life.
• Diagnose forming defects such as bow, camber, twist, width, jams, surface damage and cut-length variation.
• Determine whether production problems originate from machine condition, tooling design or wear, material variation, equipment settings or operating practices.
• Lead equipment and tooling projects through design, fabrication, installation, commissioning and final validation.
• Perform structured root-cause investigations and implement permanent mechanical and process corrective actions.
• Analyze OEE, downtime, throughput, first-pass yield, and scrap data to identify improvement opportunities.
• Develop standards, control plans, inspection methods, engineering documentation and troubleshooting guides.
• Train operators and leads on machine function, tooling requirements, process control and structured troubleshooting.

Working Conditions: The Process Engineer – Roll Form is a safety-sensitive position working directly with machinery and equipment.

• Must be able to sit and view a computer screen for extended periods.
• Must be able to bend at waist and knees, walk and stand for extended periods.
• Must be able to lift and move objects weighing up to 50 pounds when necessary.
• Must be able to bend, stoop, crawl under or over, and frequently climb (stairs).
• Specific vision abilities required by this job include close vision, distance vision, peripheral vision, and the ability to adjust focus.
• Capable of working in confined spaces and off the ground with height variances.
• Must be flexible and able to change schedule and hours of work to meet the needs of the organization.
• Must be able to travel to plant, customer, and vendor locations; occasional auto and airline travel required.
• The physical demands described here represent those that an employee must meet to perform the essential functions of this job successfully; reasonable accommodation may be available to enable individuals with a disability to perform the essential functions.

Required Qualifications

• 1+ years’ experience of hands-on manufacturing engineering, industrial maintenance, tooling engineering or production-equipment support.
• Mechanical aptitude of and hands-on experience with troubleshooting industrial equipment
• Ability to read and interpret mechanical drawings, part prints, equipment layouts, tolerances and technical specifications.
• Ability to accurately read and use precision measuring instruments, including feeler gauges, height gauges, and calipers.
• Working knowledge of motors, gearboxes, shafts, bearings, couplings, pneumatics, hydraulics, sensors, and encoders.
• Ability to apply practical engineering calculations involving force, torque, speed, loading, deflection, sizing and equipment capacity.
• Experience with root-cause analysis, corrective action and data-driven process improvement
• Strong communication, project coordination and production-floor collaboration skills.

Preferred Qualifications

• BS Degree in Mechanical Engineering, or successful apprenticeship in maintenance or tool and die.
• CAD design skills, analysis is beneficial
• Experience in roll forming or other steel related manufacturing support.
• Experience supporting the development and/or implementation of mechanical equipment or tooling modifications

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