Machining Engineer - Senior

DESCRIPTION

GPP Database Link (https://cummins365.sharepoint.com/sites/CS38534/)

Job Summary:

Plans, designs, purchases, and implements machining processes and equipment in an industrial plant.

Key Responsibilities:

Determines parts and tools needed in order to achieve manufacturing goals such as setup reduction and changeovers according to product specification; works with engineering to identify problems with product and performance and recommends solutions or enhancements. Designs, develops, implements, and analyzes technical products and systems. Performs equipment engineering design evaluations and documents results; recommends alterations to development and design to improve quality of products and/or procedures. Coaches and mentors less experienced team members. Works to improve equipment availability and capability by utilizing continuous improvement tools and working cross functionally.

RESPONSIBILITIES

Competencies:

Collaborates - Building partnerships and working collaboratively with others to meet shared objectives.

Communicates effectively - Developing and delivering multi-mode communications that convey a clear understanding of the unique needs of different audiences.

Health and Safety Fundamentals - Champions and models proactive health and safety behaviors by identifying, reporting and participating in actions to improve health and safety in order to build an interdependent culture and contribute to an injury-free workplace.

Drawing Interpretation - Integrates product design and manufacturing equipment engineering drawings to support the design and development of an optimal manufacturing process that meets product design specifications.

Equipment/Capital Procurement - Selects manufacturing equipment which meets the Cummins manufacturing specifications and meets the project or program needs.

Manufacturing Knowledge - Demonstrates the knowledge of manufacturing by correctly implementing changes in current processes, equipment, and applications to meet the function's needs and contribute towards continuous improvement.

Process Documentation - Produces written manufacturing procedures in proper sequence which are followed correctly by all approved stakeholders to establish continuity in processes and standardization.

Values differences - Recognizing the value that different perspectives and cultures bring to an organization.

Cutting Material Selection - Demonstrates understanding of the different characteristics in materials used in manufacturing processes by correctly identifying factors that impact the production process to select the appropriate material to be used for a specific manufacturing process.

Dimensional Metrology - Applies dimensional measurement science in the development and application of measurement/inspection processes that deliver capable measurement results, supporting design validation and conformity assessment meeting regulatory, customer and product requirements.

Health and Safety – Machine Guarding - Understands and implements Cummins policies, legal and other requirements by applying approved machine guarding standards on existing machines and/or through the design and procurement of new machines/equipment to reduce overall risk to as low as reasonably practicable.

Machine Programming - Creates factory floor machine programs by designing and implementing solutions to improve usage of machine and overall operation.

Material Removal Tooling and Processes - Selects the tools needed to complete a material removal process that meets the product requirements at the lowest total costs to provide products that meet the customer needs.

Measurement Process Design - Applying knowledge of Geometric Dimensioning and Tolerancing principles and knowledge of measurement technology (standards, techniques, equipment, etc) to design a measurement system that can consistently meet industry and customer requirements.

Education, Licenses, Certifications:

College, university, or degree in STEM (Science, Technology, Engineering, Math) or related field, or equivalent experience required.

This position may require licensing for compliance with export controls or sanctions regulations.

Experience:

Intermediate level of relevant work experience required.

QUALIFICATIONS

Role Summary

The Machining Engineer is responsible Machining operations of the Cylinder Block, Cylinder Head, and Camshaft machining lines. This hands-on role ensures that production targets, ensuring safety, quality, delivery, cost, manpower management, and continuous improvement across all machining operations. The role requires strong technical knowledge of CNC machining, quality compliance, and people leadership to achieve plant KPIs.

Key Responsibilities

Production & Operations Management

• Plan and execute daily/weekly production schedules to meet customer demand.
• Ensure stable operation of CNC machining lines (HMC, VMC, turning, grinding, honing, cam grinding etc.)
• Monitor OEE, cycle times, line balancing and optimize machine utilization.
• Drive adherence to machining process controls and work instructions.
• Implement tool life monitoring, tool change strategy, and fixture maintenance.

Quality & Compliance

• Ensure zero-defect machining for critical features:
• Cylinder bores, main tunnels, deck face, ports, valve seats, cam lobes etc.
• Collaborate with Quality team to maintain CP/CPK, SPC & Poka‑Yoke controls.
• Lead investigations for quality issues using 8D, 5 Why, Fishbone.
• Ensure compliance with QMS, audits, calibration and traceability requirements

Safety, Health & Environment

• Enforce 100% compliance to LOTO, PPE, machine guarding and safe operating procedures.
• Identify & eliminate safety risks (chips, coolant, lifting, ergonomics).
• Drive safety culture — Near Miss reporting, JSA, risk assessments.

People Management

• Lead a team of shift leaders, technicians, operators & apprentices.
• Conduct skill assessments, training and certification for machining competency.
• Manage shift planning, attendance, discipline and team motivation.
• Create a high-performance culture focused on teamwork and accountability.

Cost & Productivity Improvement

• Drive machining cost optimization — tool cost, cycle time, consumables, coolant.
• Lead Kaizen, Lean, Six Sigma projects for productivity improvement.
• Execute TPM/Preventive Maintenance in collaboration with Maintenance team.
• Support new product introduction (NPI) and engineering changes.

Cross‑Functional Collaboration

• Coordinate with Supply Chain, Maintenance, Quality, CI, Engineering and HSE teams.
• Ensure timely escalation and communication to leadership.
• Support customer visits, audits and plant tours.

Technical Skills & Competencies

• Strong Hands-on experience in machining cylinder blocks, heads, and cam components.
• Technical expertise in CNC HMC, VMC, Honing, Liner Boring, and Grinding machines.
• Proficiency in reading engineering drawings, GD&T, and interpreting CAM software.
• Strong knowledge of cutting tools, tool life optimization, and form tool designing.
• Analytical thinking with a strong execution orientation and problem-solving approach.
• Experience with ERP/MRP systems for production tracking.
• CNC Programming & Operation: Proficiency in G-code, M-code, and CAD/CAM software (e.g., Mastercam, Fusion 360) is required to program, simulate, and operate 3-axis to 5-axis machines.
• Blueprint Interpretation: Ability to read and understand technical drawings, including geometric dimensioning and tolerancing (GD&T), surface finish requirements, and datums.
• Precision Measurement (Metrology): Skilled use of inspection tools like micrometer gauges, calipers, and coordinate measuring machines (CMM) to verify components within micron tolerances.
• Machine Setup & Tooling: Expertise in setting up work holding fixtures, tool changes, and establishing "touch-off" points.
• Advanced Metallurgy Knowledge: Understanding of the properties of casting materials, particularly aluminum alloys and gray cast iron, to prevent deformation during cutting.
• Boring & Honing: Techniques for creating accurate cylinder bores and achieving desired surface finishes.
• Surface Milling: Techniques for flattening engine block decks and cylinder head mating surfaces.
• Valve Seat & Guide Machining: High-precision drilling, reaming, and machining for valve seat inserts and valve guides to ensure proper seating.
• Porting & Polishing: Shaping intake and exhaust ports to improve airflow (common in performance engine machining).
• Leak Testing & Quality Assurance: Conducting pressure tests on water jackets to check for porosity or cracks.
• Profile Milling & Turning: Specific techniques to generate complex cam profiles from blanks using CNC mills or specialized lathes.
• Grinding & Finishing: Utilizing vitrified grinding wheels to achieve precise surface finishes on lobes and journals.
• Heat Treatment & Straightening: Knowledge of induction hardening for lobes and straightening methods to remove distortion caused by heating.

Job Manufacturing

Organization Cummins Inc.

Role Category On-site with Flexibility

Job Type

ReqID 2426495

100% On-Site Yes

Due to the operational nature and specific job duties of this role, work is required to be completed 100% in person/On-site.