Process Engineer

Job Summary

Essential Duties and Responsibilities

• Develop, establish, validate, and document robust injection molding processes for new and existing products.
• Lead process development activities, including mold trials, process studies, capability analysis, and production validations.
• Analyze molding processes and implement improvements to increase productivity, quality, and overall equipment effectiveness (OEE).
• Troubleshoot molding defects, including flash, short shots, sink marks, burn marks, splay, warpage, dimensional variation, and cosmetic defects.
• Utilize scientific molding principles and data-driven methodologies to establish and maintain process controls.
• Conduct root cause investigations and implement corrective and preventive actions for process-related issues.
• Support new product launches, process qualifications, mold validations, and production ramp-ups.
• Develop and maintain standard process sheets, work instructions, validation documentation, and engineering records.
• Collaborate with Quality to establish process capability requirements and improve product consistency.
• Identify opportunities to reduce cycle times, scrap, downtime, material consumption, and manufacturing costs.
• Evaluate and implement process improvements involving automation, robotics, vision systems, and auxiliary equipment.
• Partner with Tooling and Maintenance teams to improve mold performance, reliability, and preventive maintenance programs.
• Lead continuous improvement projects utilizing problem-solving methodologies.
• Support production teams by providing technical guidance and training on molding processes and best practices.
• Participate in customer audits, quality investigations, and corrective action activities as required.
• Ensure compliance with safety, environmental, and company policies.

Required Qualifications

• Bachelor's degree in Engineering, Plastics Engineering, Manufacturing Engineering, Mechanical Engineering, or a related technical field.
• Minimum of 3 to 7 years of experience in plastic injection molding process engineering or advanced process development.
• Strong knowledge of injection molding equipment, molds, tooling, and resin processing.
• Experience developing and validating molding processes in a manufacturing environment.
• Knowledge of scientific molding principles and process optimization techniques.
• Experience with root cause analysis, statistical methods, and process capability analysis.
• Ability to read and interpret engineering drawings, GD&T, specifications, and quality standards.
• Proficiency with Microsoft Office and manufacturing software systems.
• Excellent analytical, organizational, and problem-solving skills.
• Strong communication and project management abilities.

Preferred Qualifications

• Bachelor's degree in Plastics Engineering.
• RJG Master Molder Certification or equivalent Scientific Molding certification.
• Experience with automation systems, robotics, and machine vision technologies.
• Experience in automotive, medical, consumer products, or other high-volume injection molding environments.
• Knowledge of DOE (Design of Experiments), Moldflow analysis, and process capability studies.

Knowledge, Skills, and Abilities

• Injection molding process development and optimization.
• Scientific molding and process validation methodologies.
• Plastic resin behavior, material drying, and material handling systems.
• Statistical Process Control (SPC) and process capability analysis.
• Root cause analysis and corrective action implementation.
• Continuous improvement methodologies.
• Project leadership and cross-functional collaboration.
• Automation and manufacturing technology integration.
• Strong technical writing and documentation skills.
• Excellent verbal and written communication skills.

Physical Requirements

• Ability to stand, walk, and move throughout the manufacturing facility for extended periods.
• Ability to occasionally lift up to 35 pounds.
• Ability to inspect molds, machines, and manufacturing equipment.
• Frequent reaching, bending, and interaction with manufacturing equipment.
• Ability to safely wear required personal protective equipment (PPE).

Work Environment

Key Performance Indicators (KPIs)

Success Factors