Process Engineer

Position Summary

The Injection Molding Process Engineer is responsible for developing, implementing, and maintaining efficient and reliable injection molding processes to ensure consistent production of high-quality parts. This position provides technical expertise in process optimization, troubleshooting, and continuous improvement, serving as a key liaison between production, maintenance, quality, and engineering functions. The Process Engineer leads process development for new product launches, supports tooling and equipment validation, and contributes to productivity, cost, and quality improvement initiatives. Additionally, this role provides technical direction and mentoring to process technicians and molding personnel, ensuring adherence to established standards, procedures, and safety requirements.

Essential Job Functions

• Plan, direct, and coordinate manufacturing equipment and processes to produce high-quality injection-molded products.
• Lead molding efforts for new program launches, process setups, and revisions.
• Troubleshoot and resolve production issues, driving continuous process improvements.
• Monitor and quantify process effectiveness, document results, and report findings to management.
• Provide training, guidance, and mentorship to process technicians and molding team members.
• Analyze, optimize, and standardize manufacturing processes to improve productivity, quality, and operational safety.

Key Responsibilities

• Assess, document, and improve existing processes to increase product quality, productivity, and Overall Equipment Effectiveness (OEE).
• Develop and validate new processes and product launches; lead equipment selection, installation, and capability trials.
• Prepare capital equipment requests using sound cost/benefit analysis.
• Collaborate with suppliers and engineers to ensure seamless equipment and material integration.
• Provide hands-on leadership and technical support to process technicians, operators, and production teams.
• Develop and maintain clear, detailed process documentation, work instructions, and standard operating procedures.
• Drive cost reduction and yield improvement initiatives through data-driven problem solving.
• Lead troubleshooting and corrective action for molding, material, and equipment issues.
• Monitor injection molds, recommend refurbishment, and maintain tooling history records.
• Interface with suppliers and customers to resolve technical issues and communicate project progress.
• Apply statistical methodologies (SPC, FMEA, Six Sigma) to improve process capability and quality.
• Champion Lean, Six Sigma, and Kaizen initiatives to eliminate waste and drive efficiency.
• Support all facility safety, environmental, and ergonomic initiatives, modeling proper PPE and safe work practices.

Qualifications:

Education & Experience

• Bachelor’s degree in Plastics, Chemical, or Mechanical Engineering required.
• 3–5 years of hands-on experience in an injection molding operation.
• Strong technical background in molding processes, tooling, equipment, materials, and quality systems.
• Proficiency in process analysis tools (SPC, FMEA, Six Sigma) and Lean Manufacturing principles.
• Demonstrated ability to lead projects, facilitate team activities, and manage multiple start-ups.
• Excellent written and verbal communication, organization, and teamwork skills.
• Strong computer skills including Word, Excel, PowerPoint; AutoCAD or SolidWorks experience preferred.
• Master Molder I certification (or equivalent) and experience with scientific molding methodology highly desired.
• Self-starter with strong problem-solving skills, capable of working independently and cross-functionally.
• Experience mentoring or providing technical guidance to others is preferred.

Soft Skills & Work Behaviors

• Analytical mindset with technical rigor and strong problem-solving ability.
• Hands-on, collaborative leader with excellent communication skills.
• Proactive, detail-oriented, and committed to continuous improvement.
• Comfortable managing multiple projects and priorities in a fast-paced environment.
• Team player with the ability to work effectively across disciplines.

Key Objectives:

• Reduce production losses and scrap, and help minimize equipment downtime.
• Improve process stability, repeatability, and product quality.
• Increase Overall Equipment Effectiveness (OEE) and process efficiency.
• Support production growth and reliability through technical excellence and continuous improvement.
• Lead cross-functional teams of operators, material handlers, and technical staff in implementing improvement projects and new automation.