POSITION SUMMARY

We are seeking a skilled and motivated Process Engineer - Injection Blow Molding to join our manufacturing team in Arlington, TX. This is a hands-on, floor-based position responsible for supporting, maintaining, and improving injection blow molding processes across multiple production lines.

The primary focus of this role is driving Overall Equipment Effectiveness (OEE), reducing scrap, improving product quality, maximizing machine uptime, and building technical expertise within the process technician team. This position requires solid experience with injection blow molding equipment, tooling, resin processing, and process development.

The ideal candidate will have 5+ years of direct injection blow molding experience and demonstrate strong troubleshooting, analytical, and collaboration skills in a fast-paced manufacturing environment.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Key Responsibilities

• Support and optimize injection blow molding processes across assigned production lines and machines.
• Drive OEE improvements through process optimization, cycle time reduction, scrap reduction, and machine reliability initiatives.
• Troubleshoot product quality defects including short shots, flash, gate defects, weld lines, warpage, thin-wall areas, and neck finish defects.
• Optimize injection parameters (injection speed, pressure, hold/pack pressure, screw recovery) and blow-station parameters (blow pressure, timing, mold and core rod temperature) to achieve consistent wall distribution and dimensional accuracy.
• Develop and maintain process specifications, setup sheets, startup procedures, and work instructions.
• Establish and maintain process windows for all active tooling (core rods, cavities, neck rings) and products.
• Support root cause investigations using structured problem-solving methodologies including 5 Why, A3, Fishbone, and PDCA.
• Collaborate with maintenance, tooling, quality, and production teams to improve process stability and throughput.
• Support mold/tooling qualifications, first article inspections, and new product launches.
• Validate and document process capability (CPK, PPK) and implement corrective actions where required.
• Conduct process audits to ensure compliance with established standards.
• Analyze production data to identify trends impacting efficiency, scrap generation, downtime, and quality.
• Support continuous improvement projects focused on productivity and cost reduction.
• Support capital projects involving new injection blow molding equipment, tooling, automation, and auxiliary systems.
• Collaborate with resin suppliers to optimize material performance and process parameters.
• Support first article and production validation runs for new products and tooling.
• Support preventive maintenance activities related to core rods, cavities, neck rings, injection units, hydraulics, cooling systems, and auxiliary equipment.
• Other duties as assigned.

Team Support Responsibilities

• Provide technical guidance and on-the-job support to Process Technicians and Setup Technicians.
• Share best practices for injection blow molding troubleshooting and startup procedures.
• Support technical training initiatives led by senior engineering staff.
• Assist production supervisors with process performance updates as needed.

SKILLS AND EXPERIENCE

Required Qualifications

• Minimum 5 years of hands-on experience in injection blow molding manufacturing.
• Working knowledge of:
  • Injection Blow Molding principles (injection, blow, and ejection stages)
  • Preform formation via injection molding onto core rods
  • Core rod, cavity, and neck ring setup and maintenance
  • Neck finish and gate quality control
  • Resin drying and material handling
  • Wall thickness control
  • Cycle optimization
• Solid troubleshooting skills involving:
  • Part quality defects
  • Machine performance issues
  • Tooling-related concerns (core rods, cavities, neck rings)
  • Material processing challenges
• Experience with HDPE, PP, PETG, LDPE, and recycled resin applications.
• Experience reducing scrap and improving OEE in a high-volume manufacturing environment.
• Working understanding of SPC, CPK, statistical analysis, and process capability studies.
• Exposure to developing:
  • SOPs
  • Process specifications
  • Control Plans
  • PFMEAs
  • Setup documentation
• Familiarity with Lean Manufacturing and Continuous Improvement methodologies.
• Good project management and organizational skills.
• Good written and verbal communication skills.
• Proficiency with Microsoft Office and manufacturing data systems.

Preferred Qualifications

• Bachelor's degree in engineering or related technical field.
• Experience with Jomar, Uniloy, Nissei ASB, Rocheleau, Aoki, or similar injection blow molding equipment.
• Experience with robotic automation and EOAT integration.
• Experience supporting tooling design and core rod/mold qualification activities.

Key Performance Indicators (KPIs)

• OEE Performance
• Scrap Reduction
• Downtime Reduction
• First Pass Yield
• Process Capability (CPK)
• Labor Efficiency
• Material Utilization
• Preventive Maintenance Compliance
• Technical Skill Growth
• New Product Launch Success

PHYSICAL DEMANDS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. The employee is frequently required to stand and walk. The employee is occasionally required to sit. The employee must occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus. While performing the duties of this job, the employee is regularly required to talk and listen.

WORK ENVIRONMENT

Our facility operates with machinery that can be loud and requires ear protection and eye protection. The manufacturing environment can be fast-paced and physically demanding, with exposure to various materials and processes. We prioritize safety and cleanliness, providing all necessary protective gear and maintaining strict hygiene standards. Despite the challenging conditions, we foster a collaborative and supportive atmosphere where teamwork and professional growth are highly valued.