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 preve

📌 Senior Resistance Welding Process Engineer (Tijuana)
🏢 Schneider Electric
📍 Tijuana