Buckeye Fire Equipment
DOT Cylinder Manufacturing Engineer
Buckeye Fire Equipment, Kings Mountain, North Carolina, United States, 28086
Role Summary
You will be the technical owner for DOT cylinder manufacturing—from raw material through forming, welding, heat treatment, machining, finishing, and hydro/burst testing—ensuring throughput, cost, quality, and full regulatory compliance.
What You’ll Do
Process Ownership:
Define, validate, and continuously improve end-to-end manufacturing processes for steel/aluminum cylinders (deep draw/spin, necking, welding, heat treat, threading, shot blast, paint/powder, assembly).
Regulatory Compliance:
Develop and maintain procedures, travelers, and records to meet
49 CFR Parts 171–180 (esp. Part 178 for cylinders) , CGA standards, and related UN/DOT requirements; support audits and approvals.
Quality & Testing:
Establish inspection and test plans (hydrostatic, burst, leak, NDT as applicable), MSA/GR&R, control plans, reaction plans; disposition nonconforming product and drive root‑cause and corrective actions (8D/5‑Why, fishbone).
Tooling & Equipment:
Specify, design, and maintain dies, mandrels, weld tooling, fixtures, gages; write equipment URS, lead FAT/SAT, and own process qualification & capability (Cp/Cpk).
Throughput & Cost:
Implement Lean/CI projects (SMED, line balancing, standard work, waste elimination) to increase OEE, reduce scrap/rework, and improve yield; deliver clear ROI.
Documentation:
Create PFMEAs, process flow diagrams, SOPs/Work Instructions, and training materials; keep DMR/DMR‑like records current in our QMS (ISO 9001).
Supplier Collaboration:
Qualify raw materials (tube, coil, bar), weld wire, valves/fittings; support PPAP‑like submissions, COAs, and incoming inspection criteria.
Safety & EHS:
Engineer processes that meet OSHA and plant safety requirements (lockout/tagout, guarding, ventilation), especially for pressure testing and heat treat operations.
Cross‑Functional Support:
Partner with Product Engineering, Quality, Maintenance, and Production to launch new cylinders and sustain existing SKUs with minimal downtime.
What You’ll Bring
Education:
BS in Mechanical/Manufacturing/Welding/Materials Engineering (or equivalent experience).
Experience:
5+ years in pressure‑vessel or cylinder manufacturing, metal forming, or closely related high‑compliance production (fire protection, industrial gas, aerospace, automotive tanks).
Regulatory Literacy:
Working knowledge of
DOT/49 CFR
for cylinders, CGA guidance, and relevant test/marking/recordkeeping requirements; familiarity with UL/NFPA product implications is a plus.
Process Skills:
Hands‑on with forming/spinning/drawing, welding (GMAW/GTAW/PAW), heat treatment, machining/threads, leak/hydro/burst testing, and finishing lines.
Quality Tools:
Strong with PFMEA, control plans, MSA, SPC, capability studies, 8D; proficient in Minitab (or equivalent).
Design/Industrialization:
CAD (SolidWorks or similar) for tooling/fixture design; ability to generate URS, IQ/OQ/PQ, and process validations.
Soft Skills:
Data‑driven, shop‑floor presence, clear communicator, able to lead cross‑functional teams and train operators/techs across shifts.
Nice to Have
Experience with ASME, UN packaging, or transport marking/labeling for pressure receptacles.
Knowledge of automation/PLC basics, sensor selection, and interlocks for test stands.
Prior involvement with UL/FM product certifications and NFPA 10 implications for extinguisher assemblies.
Success Metrics (First 6–12 Months)
OEE +10 points
on key forming/weld/test bottlenecks.
Zero regulatory findings
in internal/external audits; 100% on‑time/accurate test and traceability records.
Cycle‑time reduction (SMED) delivering ≥
15% throughput gain
on at least one constraint operation.
Successfully
launch
at least one new or revised cylinder SKU with validated processes and training completed.
Physical & Work Conditions
On‑the‑floor role around forming presses, spinning lathes, weld cells, furnaces, and test stands; PPE required.
Ability to lift 35 lbs occasionally and stand/walk for extended periods; occasional off‑shift/ weekend support during trials or launches.
Buckeye Fire Equipment provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.
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What You’ll Do
Process Ownership:
Define, validate, and continuously improve end-to-end manufacturing processes for steel/aluminum cylinders (deep draw/spin, necking, welding, heat treat, threading, shot blast, paint/powder, assembly).
Regulatory Compliance:
Develop and maintain procedures, travelers, and records to meet
49 CFR Parts 171–180 (esp. Part 178 for cylinders) , CGA standards, and related UN/DOT requirements; support audits and approvals.
Quality & Testing:
Establish inspection and test plans (hydrostatic, burst, leak, NDT as applicable), MSA/GR&R, control plans, reaction plans; disposition nonconforming product and drive root‑cause and corrective actions (8D/5‑Why, fishbone).
Tooling & Equipment:
Specify, design, and maintain dies, mandrels, weld tooling, fixtures, gages; write equipment URS, lead FAT/SAT, and own process qualification & capability (Cp/Cpk).
Throughput & Cost:
Implement Lean/CI projects (SMED, line balancing, standard work, waste elimination) to increase OEE, reduce scrap/rework, and improve yield; deliver clear ROI.
Documentation:
Create PFMEAs, process flow diagrams, SOPs/Work Instructions, and training materials; keep DMR/DMR‑like records current in our QMS (ISO 9001).
Supplier Collaboration:
Qualify raw materials (tube, coil, bar), weld wire, valves/fittings; support PPAP‑like submissions, COAs, and incoming inspection criteria.
Safety & EHS:
Engineer processes that meet OSHA and plant safety requirements (lockout/tagout, guarding, ventilation), especially for pressure testing and heat treat operations.
Cross‑Functional Support:
Partner with Product Engineering, Quality, Maintenance, and Production to launch new cylinders and sustain existing SKUs with minimal downtime.
What You’ll Bring
Education:
BS in Mechanical/Manufacturing/Welding/Materials Engineering (or equivalent experience).
Experience:
5+ years in pressure‑vessel or cylinder manufacturing, metal forming, or closely related high‑compliance production (fire protection, industrial gas, aerospace, automotive tanks).
Regulatory Literacy:
Working knowledge of
DOT/49 CFR
for cylinders, CGA guidance, and relevant test/marking/recordkeeping requirements; familiarity with UL/NFPA product implications is a plus.
Process Skills:
Hands‑on with forming/spinning/drawing, welding (GMAW/GTAW/PAW), heat treatment, machining/threads, leak/hydro/burst testing, and finishing lines.
Quality Tools:
Strong with PFMEA, control plans, MSA, SPC, capability studies, 8D; proficient in Minitab (or equivalent).
Design/Industrialization:
CAD (SolidWorks or similar) for tooling/fixture design; ability to generate URS, IQ/OQ/PQ, and process validations.
Soft Skills:
Data‑driven, shop‑floor presence, clear communicator, able to lead cross‑functional teams and train operators/techs across shifts.
Nice to Have
Experience with ASME, UN packaging, or transport marking/labeling for pressure receptacles.
Knowledge of automation/PLC basics, sensor selection, and interlocks for test stands.
Prior involvement with UL/FM product certifications and NFPA 10 implications for extinguisher assemblies.
Success Metrics (First 6–12 Months)
OEE +10 points
on key forming/weld/test bottlenecks.
Zero regulatory findings
in internal/external audits; 100% on‑time/accurate test and traceability records.
Cycle‑time reduction (SMED) delivering ≥
15% throughput gain
on at least one constraint operation.
Successfully
launch
at least one new or revised cylinder SKU with validated processes and training completed.
Physical & Work Conditions
On‑the‑floor role around forming presses, spinning lathes, weld cells, furnaces, and test stands; PPE required.
Ability to lift 35 lbs occasionally and stand/walk for extended periods; occasional off‑shift/ weekend support during trials or launches.
Buckeye Fire Equipment provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.
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