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Job Title: Mechanical Engineer – Roll Reduction Mill & Manufacturing Systems
Location: Houston
Type of Role: Direct Hire
Schedule: 40 hours/week on site
Rate: DOE
Full Benefit package
Our client is seeking a Mechanical Engineer – Roll Reduction Mill & Manufacturing Systems to support the design, operation, optimization, and maintenance of manufacturing processes used to produce advanced downhole heater systems. This role is responsible for ensuring the roll‑reduction mill and associated thermal‑mechanical forming processes operate safely, efficiently, and within strict engineering and quality specifications. The engineer will develop and maintain manufacturing procedures, coordinate tooling and equipment improvements, and work closely with operations, quality, and product engineering teams to deliver high‑performance heater components for use in conventional and unconventional oil & gas wells.
Essential Job Duties and Responsibilities
- Own the design, operation, and continuous improvement of the roll‑reduction mill used in heater manufacturing, including setup parameters, reduction passes, roll geometry, and material handling workflows.
- Develop and document manufacturing processes, including process sheets, work instructions, quality checkpoints, heat‑treat cycles, and dimensional control steps.
- Create and maintain detailed mechanical designs, tooling drawings, and mill component schematics required to support production.
- Design and engineer custom tooling, including rolls, guides, fixtures, and forming dies tailored to alloy type, reduction schedule, and product geometry.
- Perform mechanical and thermal calculations relating to forming forces, roll loading, material flow, temperature effects, and equipment capability.
- Monitor and analyze mill performance data to identify process variations, dimensional non‑conformance, or equipment degradation; take corrective action as required.
- Support daily manufacturing operations, providing hands‑on technical guidance during setup, troubleshooting, changeovers, and corrective maintenance.
- Lead root‑cause investigations related to process deviations, equipment failures, or product non‑conformance; develop corrective and preventive actions (CAPA).
- Collaborate with Quality, Operations, and Product Engineering to ensure heater system components meet mechanical, metallurgical, and dimensional specifications.
- Manage Bills of Materials (BOMs), routing structures, tooling inventories, and maintenance documentation for mill‑related manufacturing systems.
- Ensure compliance with relevant manufacturing standards, internal quality practices, metallurgical requirements, and safety protocols.
- Drive continuous improvement initiatives, including cycle‑time reduction, tooling life optimization, scrap reduction, and equipment upgrades.
- Support capital equipment projects, including specification, procurement, installation, commissioning, and validation of mill or upstream/downstream equipment.
- Stay current on manufacturing technologies, including roll‑forming, tube‑reducing, metal heat treatment, and specialty alloy processing.
Minimum Qualifications
- Bachelor’s degree in mechanical engineering, manufacturing engineering, materials engineering, or a related discipline.
- 5–10 years of experience in manufacturing engineering, preferably involving metal forming, roll‑reduction mills, rotary reducers, tube forming, or hot‑work processes.
Core Competencies
- Hands‑on experience supporting industrial mechanical equipment, including troubleshooting, setup, and operational optimization.
- Strong understanding of metallurgy, especially heat‑affected behavior during mechanical forming of alloys used in high‑temperature or downhole applications.
- Track record in utilization of advanced modeling tools to simulate mechanical and thermal systems (FEA & CFD).
- Demonstrated experience designing tooling, rolls, or forming dies in CAD.
- Proficiency in generating mechanical drawings, tooling schematics, BOMs, and work instructions.
- Familiarity with Manufacturing Quality Systems, SPC, tolerance stack‑ups, and dimensional control methods.
- Strong mechanical analysis skills, including stress, strain, thermal effects, and mechanical loading.
- Excellent collaboration and communication abilities across production, maintenance, engineering, and quality groups.
- Ability to support multiple production lines and engineering packages simultaneously.
- High attention to detail and strong documentation discipline