Senior Process EngineerOverviewThe Senior Process Engineer is responsible for developing, optimizing, and troubleshooting injection molding processes to ensure efficient, high-quality, and cost-effective production. This role requires working with cross-functional teams to improve process stability, reduce waste, and drive continuous improvement initiatives. The engineer will play a key role in tooling qualifications, process standardization, and developing best practices in molding operations.
Responsibilities- Develop, implement, and optimize injection molding processes to improve efficiency, quality, and cycle times.
- Troubleshoot and resolve molding defects, tooling issues, and process variations using root cause analysis techniques.
- Utilize scientific molding principles and process optimizations tools including Design of Experiments to establish capable and consistent molding processes.
- Assist with new production equipment installation and qualification, providing feedback on suitability, performance and reliability.
- Lead process development for tool qualifications and test runs supporting both new product introductions and capacity tooling.
- Work closely with tooling engineers, maintenance teams, and production staff to enhance mold performance and longevity.
- Standardize process documentation, including work instructions, SOPs, and process sheets.
- Implement continuous improvement projects focused on cycle time reduction, scrap reduction, and process efficiency.
- Research and recommend new molding technologies, automation, and auxiliary equipment to enhance production capabilities.
- Provide technical leadership and training to engineers, technicians, and production personnel.
- Ensure compliance with all quality standards and company policies.
- Actively represent the processing capability during mold design reviews and DFM evaluations to insure processing consideration are included in the tooling design cycle.
- Provide on-site support for tooling trials and evaluations at tooling vendors
- Recommend resins and additive packages to support product performance requirements and manufacturing needs while insuring all material-based safety protocols and PPE needs are understood and met.
Must Haves- Bachelor's degree in Mechanical engineering, Plastics engineering, or a related field.
- 7+ years of experience in injection molding process development, tooling, and manufacturing with a focus on tight tolerance, precision injection molding.
- Formal Master Molder or similar training RJG, AIM, etc. a strong plus
- Strong understanding of polymer materials, mold construction, and processing parameters with a focus on engineering grade resins including PEI, PBT, and PC/ABS.
- Expertise in scientific molding techniques, mold flow analysis, and process validation methodologies.
- Hands-on experience with injection molding machines, robotics, and automation systems.
- Familiarity with lean manufacturing principles, Six Sigma methodologies (Green/Black Belt preferred), and SPC.
- Proficiency in troubleshooting molding defects such as flash, short shots, burns, warpage, and splay.
- Strong analytical, problem-solving, and project management skills.
- Demonstrated ability to make data-driven decisions using data analysis tools and techniques.
- Effective communication and teamwork abilities for cross-functional collaboration.
What We Offer- Competitive base salary with performance-based bonus potential
- 4 weeks of PTO to relax and recharge
- Health, dental, and vision plans to support you and your family
- 401(k) retirement savings plan with employer match and planning resources
- A collaborative, team-based culture focused on innovation and quality
- Paid holidays and employee recognition programs
- Opportunities to work with advanced molding technologies and infrastructure systems
- STEM outreach and community engagement initiatives
