We are seeking a highly skilled Senior Plastics Process Engineer focusing primarily on Factory Integration & Launch to lead the development, validation, and integration of injection molding processes, tooling, and automation systems within manufacturing operations. This role serves as a technical leader responsible for new product introduction (NPI), transfer of work (TOW), equipment startup, and process optimization ensuring excellence in Safety, Quality, Cost, and Delivery (SQCD). The role also has a strong focus on Maintenance & Repair (M&R) cost reduction and leveraging digital and AI-driven solutions to improve operational performance. Position Senior Plastics Process Engineer Location USA, Louisville, KY How You'll Create Possibilities Injection Molding Process Development & Validation • Develop, optimize, and validate injection molding processes for new and existing products • Establish scientifically developed molding processes using RJG principles, SPC, and DOE methodologies • Define process windows, parameter controls, and ensure repeatability • Perform machine qualification, capability studies, and process validation • Lead mold trials from initial sampling through PPAP approval Tool Trials, Launch & Factory Integration • Lead tool trials and production readiness for NPI and TOW • Drive integration and startup of molding tools, presses, and automation • Support robotics programming and EOAT optimization • Ensure stable production ramp-up Troubleshooting, Cost Reduction & Continuous Improvement • Troubleshoot molding defects, automation issues, and equipment performance losses • Lead root cause analysis and corrective actions for safety, quality, and cost issues • Drive M&R cost reduction through equipment reliability improvements and failure elimination • Identify and eliminate chronic downtime drivers and maintenance waste • Improve OEE, scrap reduction, cycle time, and labor efficiency • Apply Lean manufacturing and structured problem-solving methodologies Digital, Data & AI-Enabled Manufacturing • Leverage AI and advanced analytics to identify cost reduction opportunities and predict equipment failures • Utilize RJG eDART, CoPilot, and SPC systems to monitor and optimize process performance • Apply data-driven insights to reduce scrap, improve yield, and enhance process stability • Partner with digital and IT teams to deploy AI tools for predictive maintenance and process optimization • Drive adoption of digital technologies to improve decision-making and operational visibility Project Leadership • Lead projects from concept through production launch • Coordinate cross-functional teams • Manage timelines, deliverables, and launch readiness What You'll Bring to Our Team • Bachelor's degree in Engineering or equivalent experience • 5+ years injection molding experience • Strong RJG knowledge (eDART, CoPilot) • Experience with robotics, EOAT, and mold trials • Strong troubleshooting and problem-solving skills Preferred Qualifications • RJG Master Molder certification • Robot programming experience • Lean manufacturing experience • PPAP and DOE knowledge