Process Engineer-Plastics

The Process Engineer is responsible for the development, optimization, and troubleshooting of all plastic injection molding processes to ensure efficient, high-quality, and consistent production. This role works closely with Process Technicians, Tool Room personnel, Quality, Maintenance, and cross-functional manufacturing teams to improve cycle times, reduce scrap, maintain quality standards, and increase overall efficiency. The position also supports new product introductions, equipment upgrades, and continuous improvement initiatives in high-speed, thin-wall packaging applications.

PRIMARY DUTIES:

Process Development & Optimization:

• Develop, document, and optimize injection molding processes for new and existing molds.
• Provide technical leadership and hands-on support to Process Technicians and Molding Operators.
• Analyze process data and implement improvements to reduce cycle times, scrap rates, and downtime.
• Lead process validation activities, including DOE, IQ/OQ/PQ protocols, and capability studies.
• Ensure compliance with safety, environmental, and regulatory standards, including GMP/SQF where applicable.

Collaboration & Troubleshooting:

• Partner with Quality, Tooling, Maintenance, and Production teams to resolve part defects and mold issues.
• Evaluate mold performance and recommend tooling improvements.
• Support predictive and preventive maintenance strategies to improve uptime and reliability.
• Collaborate with Project Management to support new product development and upgrades to molding, automation, and downstream packaging systems.

Automation & Technology Integration:

• Integrate high-speed molding cells with robotics, vision inspection, and downstream high-speed packaging systems.
• Assist in selecting, installing, and commissioning injection molding machines and auxiliary equipment.
• Implement automation improvements and labor optimization strategies.

Continuous Improvement & Efficiency:

• Lead and participate in Lean Manufacturing and Six Sigma initiatives to improve OEE and reduce waste.
• Conduct labor studies, cycle time analysis, and process capability improvements.
• Drive significant cost savings through CI projects utilizing a Six Sigma Project Charter.

Education, Training & Experience:

• Bachelor’s Degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, or a related technical field, or equivalent experience.
• Continuous Improvement Green Belt certification preferred.
• CI experience leading a significant cost-saving project utilizing a Six Sigma Project Charter.
• High-speed injection molding experience required, specifically in thin-wall packaging applications with extremely fast cycle times.
• Experience developing scientific molding processes from the ground up.
• Experience conducting DOE studies to validate and optimize molding parameters.
• Experience with mold trials, start-up procedures, and process troubleshooting.
• Experience integrating molding cells with robotics, vision inspection, and downstream packaging systems.
• Formal training or certifications in scientific molding or RJG technology preferred.
• Lean Manufacturing or Six Sigma certification advantageous.
• At least 5 years of practical experience in plastic injection molding within a manufacturing setting.
• Experience with validation protocols (IQ/OQ/PQ) in regulated manufacturing environments.

QUALIFICATIONS

• Understanding of SPC, with the ability to read control charts and improve process capabilities.
• Knowledge of polypropylene, polyethylene, and other thin-wall packaging-grade resins, including shrinkage, flow, and cooling behavior.
• Strong understanding of OEE with the ability to track and drive improvements.
• Collaborates effectively with tooling, quality, maintenance, and operations personnel.
• Proficiency in statistical process control and root cause analysis.
• Proficient in Microsoft Office and familiar with ERP and MES systems.

RELATIONSHIPS:

All employees-all departments

SUPERVISORY RESPONSIBILITIES:

None