Job Summary:The
Senior Process Engineer plays a vital role in the injection molding team by creating, analyzing, improving, and adjusting molding processes to optimize cost, quality, and throughput of the molding operations. The Molding Process Engineer will be responsible for sampling, process development, and documentation of new injection molds as well as existing molds; in addition to mold validation and sampling.
Pay: $120,000 - $135,000 annually
Essential Duties/Responsibilities:- Develop and optimize injection molding processes for new and existing molds using scientific molding principles.
- Lead mold sampling, process development, validation activities, and production launches.
- Work with Quality to establish and maintain consistent part quality, process controls, and monitoring systems.
- Troubleshoot molding processes, tooling, materials, automation, and equipment issues.
- Collect and analyze process data to identify opportunities to improve quality, efficiency, cycle time, and process capability.
- Document and maintain process sheets, setup standards, work instructions, and validation documentation.
- Assist with the creation and maintenance of Control Plans, PFMEAs, process flows, and related manufacturing documentation.
- Participate in mold design reviews, material reviews, and formal print reviews.
- Provide input on mold, tooling, automation, and equipment designs to ensure alignment with process requirements and manufacturing objectives.
- Develop and execute Design of Experiments (DOE), capability studies, and process validations for new and modified processes.
- Provide technical leadership and support for cost reduction, scrap reduction, cycle time improvement, and continuous improvement initiatives.
- Work with Operations, Tooling, Maintenance, Engineering, and Quality to develop, strengthen, and maintain troubleshooting and process improvement activities.
- Serve as a technical resource for resolving molding defects, dimensional issues, and process-related production challenges.
- Mentor and train Process Technicians, Setup Technicians, and Operations personnel on scientific molding and process control practices.
- Use Lean Manufacturing, Six Sigma (DMAIC), SPC, DOE, and other statistical tools to analyze process performance and drive continuous improvement.
- Support KPI tracking and reporting related to scrap, efficiency, downtime, OEE, cycle time, and process capability.
- Other duties as assigned.
Qualifications & Requirements:- Bachelor's degree in Engineering (Manufacturing, Mechanical, Plastics, Industrial) and
- 8+ years of hands-on process engineering experience in plastics manufacturing, with strong injection molding expertise
- 5+ years of experience with ISO 13485 or similar regulated industry quality system requirements preferred
- Demonstrated experience developing, documenting, optimizing, and troubleshooting injection molding processes in a production environment.
- Strong knowledge of scientific molding, decoupled molding, process window development, tooling, resins, drying requirements, and secondary operations.
- Experience with mold sampling, process validation, capability studies, root cause analysis, corrective/preventive actions (CAPA), and MRB support.
- Experience using Computer Aided Design (CAD) software; experience with Moldflow, RJG/eDART, cavity pressure monitoring, or similar tools is preferred.
- Working knowledge of Lean Manufacturing, Six Sigma, DOE, SPC, GD&T, PFMEA, control plans, ERP/MES systems, and data analysis tools.
- Strong communication, leadership, mentoring, problem-solving, and project management skills with the ability to influence cross-functional teams.
- Experience in writing, reading and interpreting the documentation of designs and production processes.
Physical Requirements: - Ability to stand, walk, and move around the production floor for extended periods.
- Capable of lifting and carrying heavy objects weighing up to 50 pounds.
- Manual dexterity and hand-eye coordination for handling small tools, machine components, and molds.
- Ability to work in a fast-paced environment and adapt to changing priorities.
- Comfortable wearing personal protective equipment (PPE) such as safety glasses, gloves, and ear protection.
- Occasional bending, kneeling, and reaching to access equipment and perform maintenance tasks.
- Good vision and color perception for inspecting parts and identifying any defects or abnormalities.
- Ability to work in temperature-controlled environments and withstand exposure to noise levels associated with manufacturing machinery.
- Ability to receive, comprehend and utilize required training from OSHA and Company including but not limited to the following:
- Hazard Communication
- Lock Out/Tag Out
This job description is intended to describe the general nature and level of work being performed. It is not an exhaustive list of all responsibilities, duties, and skills required. Employees may be required to perform other duties as assigned.
