Process Engineer

Role Overview

The Process Engineer plays a vital role in creating, stabilizing, and maintaining efficient molding processes that ensure production is safe, consistent, and cost-effective. This position is responsible for the full lifecycle of process definition, control, troubleshooting, and ongoing optimization within our injection molding operations. By documenting processes, enforcing controls, and providing training, the Process Engineer works alongside Operations, Maintenance, Tooling, and Quality teams to minimize downtime, reduce scrap, and eliminate variability. This is a hands-on, floor-based position that is essential to the stability and performance of our plant.

Core Responsibilities

• Develop scientifically validated process windows for PC, PP, and related resins.
• Maintain optimal settings by managing melt temperature, shear, injection velocity, pack/hold pressure, and cooling efficiency to ensure high-quality output.
• Utilize knowledge of crystallization, viscosity, and thermal sensitivity to inform process design.
• Manage all standard work, process setup documentation, and parameter control limits.
• Mentor and train the team to ensure molding processes are executed and maintained correctly to protect production integrity.
• Conduct engineering analysis to resolve complex defects such as splay, burns, voids, sinks, and dimensional instability.
• Identify correlations between material conditions, mold design, and machine dynamics to address root causes of defects.
• Drive permanent solutions by leveraging DOE, SPC data, and cavity pressure trends.
• Collaborate with Maintenance and the Tool Room to improve part release, venting, ejection, and cooling circuit performance.
• Assist with new tool introductions, steel-safe modifications, and mold trials.
• Verify that molds are technically capable of supporting established process windows.
• Provide technical guidance regarding mold PM requirements and wear components.
• Take ownership of molding process capability metrics like Cp/Cpk.
• Implement SPC across critical part characteristics and process parameters.
• Shift quality control efforts from reactive inspection to proactive process management.
• Utilize data-driven analysis to support investigations into customer complaints, quality holds, and scrap.
• Oversee the validation and commissioning of hybrid, hydraulic, and electric presses, along with auxiliary equipment like robots and material handling systems.
• Ensure machine capability aligns with mold and material requirements.
• Enhance cycle times while protecting mold longevity and part performance.
• Maintain strict adherence to all quality, environmental, and safety policies.
• Facilitate effective shift communication to ensure consistent process execution.
• Perform additional duties as requested.

Education and Experience

Required

• Bachelor’s degree in Mechanical, Plastics, Manufacturing, or a related Engineering field.
• Seven to ten years of practical experience in injection molding process engineering.
• Comprehensive understanding of PC and PP material behavior in molding.
• Demonstrated ability to solve complex process issues through data analysis.

Preferred

• Scientific molding certification, such as RJG Master Molder I or II.
• Exposure to Six Sigma, SPC, and DOE methodologies.
• Experience working in high-volume manufacturing environments with multiple presses.

Knowledge, Skills, and Abilities

• Extensive expertise in process parameters, material behavior, mold design, and injection molding.
• Ability to interpret process data, specifications, and technical drawings.
• Strong problem-solving and analytical capabilities.
• Experience with root cause analysis, quality improvement tools, and statistical process control.
• Strong teamwork and communication skills.
• Capacity to work independently and drive process improvement initiatives.
• Familiarity with continuous improvement and Lean Manufacturing practices.
• Proficiency in manufacturing execution systems (MES) and MS Office.

Required Proficiencies

• Bachelor's Degree
• Data Analysis and Manipulation
• Continuous Improvement
• Measurement System Analysis (MSA)
• 5 Why (Root Cause Analysis Method)
• Fishbone Diagram (Ishikawa Diagram)
• Advanced Product Quality Planning (APQP)
• Supplier Management
• Motor Replacement/Repair/Maintenance
• Manufacturing Instruction (MI)
• Troubleshooting Industrial Automation Equipment
• Process Engineering
• Production Optimization
• Design for Manufacturability (DFM)
• Design for Assembly (DFA)
• Kaizen
• Quality Control Experience
• Mechanical Design & Engineering
• Tolerance Analysis
• Electrical / Electronic Systems
• Lean Manufacturing Principles
• Six Sigma Experience
• Operational Risk Management
• Production Planning & Scheduling
• High-level Operations Analysis
• Quality Control Data Analysis
• Budgeting / Forecasting Experience
• Engineering Degree
• Root Cause Analysis
• Process Development
• Non-conforming Product ID