Process Engineer

Duties:

• Provides technical expertise in developing, optimizing, and scaling plastics processing operations, including injection molding and thermoforming, from R&D and pilot stages through full-scale production.

• Evaluates and refines tooling for both injection molding and thermoforming, from initial design through production performance, in collaboration with Engineering and the Mold Shop.

• Solves complex technical problems independently or cross-functionally, including process deviations, equipment failures, and material inconsistencies.

• Conducts process capability studies and root cause analyses to resolve manufacturing and product development issues; supports and implements corrective actions.

• Partners with Product Development to align process strategies with R&D objectives for both molded and formed plastic components.

• Designs and executes experiments, collects and analyzes process data, and delivers data-driven recommendations. Applies strong knowledge of SPC, Cpk, DOE, and FMEA methodologies.

• Provides hands-on technical leadership and training to Machine Operators, Setup Mechanics, Setup Technicians, and Process Technicians across injection molding and thermoforming operations.

• Builds and maintains strong vendor relationships to support equipment selection, tooling development, and process improvements for new and existing programs.

• Supports troubleshooting, repair, and preventive maintenance activities across manufacturing equipment and systems.

• Leads or supports commercialization activities, including process validation and production readiness, with flexibility to work varied hours or shifts as needed.

Requirements:

• Minimum of 15 years of progressive experience in plastics manufacturing, with significant exposure to injection molding and/or thermoforming; or a two-year technical degree with at least 10 years of relevant experience. Engineering degree preferred.

• Demonstrated ability to manage multiple projects simultaneously with minimal supervision.

• Strong technical expertise in plastics processing, including injection molding, thermoforming, tooling, materials, product design, and secondary/automated operations.

• Proven problem-solving ability, including data collection, analysis, and implementation of solutions; Lean Six Sigma experience preferred.

• Ability to interpret complex technical data, drawings, and mathematical models; strong understanding and application of statistical analysis required.

• High level of mechanical aptitude, including knowledge of mechanical systems, high and low voltage systems, and basic PLC troubleshooting skills.