The Senior Molding Process Engineer applies plastics engineering and principles to the design of tools, manufacturing process development, documentation, and testing for molded parts. Development of responsibilities for this position will include Molding Operations line support activities as well as product / process improvements including cost reductions in the manufacturing process, support new product transfers to manufacturing, including tools transfers, support in the technology development in accordance with company strategies, support the transfer of manufacturing methods and or technologies within the company and or external business partners, develop and maintain all manufacturing documentation / work instructions. Demonstrated knowledge in Design for Manufacturability, Lean Methodologies / Tools, Design of Experiments (DOE), Statistical Process Control (SPC), and product and process characterizations. Development of Process Failure Mode Effect Analysis (pFMEA) during manufacturing process development and change. Investigates product failures and develops methods to prevent recurrence.
Duties and Responsibilities:
- Develop, qualify, and validate injection molding and ancillary processes/tooling for new precision parts/molds.
- Support existing products with sustaining process engineering for a 40+ machine captive molding operation including troubleshooting material, tooling, process, and equipment issues.
- Establish work instructions, proper Moldability ranges, manufacturing procedures, and quality control input.
- Assist in procuring new and replacement tooling.
- Assist in procuring related equipment including molding machines and developing capital budgets.
- Assist in developing new plastic parts from a "Design for Manufacture" point of view, including material recommendations.
- Execute cost reduction and continuous improvement projects.
- Quote part and tooling costs including budget estimates.
- Execute part change orders.
- Lead process/tooling training programs, especially with mold technicians.
- Assist in mold transfer programs.
- Write reports to management.
- Report directly to the Engineering Manager, and indirectly to Project Managers for new products.
Leave your footprint
- 10 years minimum plastics process engineering and five years minimum tooling experience in a precision/cosmetic injection molding plant (preferably medical products, especially devices).
- Technical injection molding process and tooling skills (see below).
- Detailed understanding of plastic part design, polymer materials, tooling, equipment (preferably including some automation), processing, validations (preferably medical), writing and communication skills.
- Clear understanding of what it takes to injection mold quality parts, including equipment capability.
- Preferred Bachelor of Engineering (preferably manufacturing but chemical, mechanical, or electrical acceptable).
- Self-motivated, Proven team player with ability to technically lead and teach.