Process Engineer

Responsibilities

POSITION OVERVIEW:

The Injection Molding Process Engineer is responsible for developing, optimizing, and sustaining molding processes to ensure high-quality, cost-effective production. This role focuses on process stability, scrap reduction, cycle time optimization, and implementation of continuous improvement initiatives. The engineer will work cross-functionally with tooling, maintenance, quality, and production teams to troubleshoot issues and drive measurable performance gains. This could be a second shift position.

CORE RESPONSIBILITIES:

• Develop, validate, and optimize injection molding processes for new and existing programs
• Lead structured problem-solving activities (DOE, root cause analysis, SPC) to reduce scrap and improve quality
• Establish and document standard processing parameters, setup sheets, and work instructions
• Support mold trials, qualification runs, and new product launches
• Troubleshoot molding defects such as short shots, flash, warp, dimensional variation, and cosmetic issues
• Drive cycle time reduction, material usage optimization, and overall equipment efficiency (OEE) improvements
• Collaborate with tooling and maintenance teams to improve mold performance and reliability
• Analyze process data and trends to identify opportunities for continuous improvement
• Support validation activities (IQ/OQ/PQ where applicable)
• Train technicians and operators on best practices, process standards, and troubleshooting techniques
• Ensure adherence to safety, quality, and environmental standards
• Lead continuous improvement and cost saving initiatives
• Identify root causes and implement permanent corrective actions for process related functions
• Assist in the development and coordination of project plans, review vendor proposals, manage team activities, communicate changes, provide progress updates, and complete on time and within budget.

QUALIFICATIONS (must have):

• Bachelor's degree in engineering (Plastics, Mechanical, Manufacturing, or related field) or equivalent firsthand experience
• 10+ years of experience in injection molding process engineering or equivalent technical role.
• Strong understanding of scientific molding principles (fill, pack, hold, cooling optimization)
• Proven experience with troubleshooting molding defects and process instability
• Experience running and analyzing Design of Experiments (DOE)
• Familiarity with thermoplastics materials.
• Ability to interpret part drawings and CAD data.
• Strong data analysis skills and experience using SPC tools
• Experience with molding machines, hot runner systems, and auxiliary equipment
• Proficiency in Microsoft Excel and standard manufacturing tools

QUALIFICATIONS (beneficial):

• RJG Master Molder certification or similar scientific molding training
• Familiarity with mold flow analysis (Moldflow or equivalent)
• Knowledge of automation systems (robotics, conveyors, vision inspection)
• Experience with Six Sigma / Lean Manufacturing methodologies
• Knowledge of project management principles and practices

IDEAL CANDIDATE PROFILE:

• Analytical, with a data-driven approach to problem solving
• Continuous improvement mindset with a passion for reducing waste and improving efficiency
• Effective communicator who can translate technical concepts to operators and leadership
• Meticulous with a focus on process consistency and repeatability
• Able to manage multiple priorities in a fast-paced manufacturing environment
• Collaborative, and capable of influencing cross-functional teams

Company Benefits:

Health & Welfare Benefits: Medical and prescription drug plans, telemedicine (with medical plan), High-Deductible Health Plan (HDHP) and Health Savings Account (HSA), dental and vision plans, virtual physical therapy*, an employee assistance program (EAP)*, and voluntary accident, critical illness, and hospital indemnification programs.

Financial Benefits: Retirement 401k program with company match, an employee stock purchase plan (voluntary), financial wellness planning*, paid parental leave*, flexible spending accounts (FSA) for child care and health care, short-term and long-term disability*, basic life insurance, accidental death and dismemberment (AD&D)*, adoption financial reimbursement*, tuition reimbursement*, voluntary life insurance (for employees, spouses, and children), and voluntary identity theft and fraud protection.

*100% paid by ADS.