Molding Process Engineer

Molding Process Engineer

Seeking a Molding Process Engineer with experience in scientific molding, injection molding, validation, and troubleshooting to optimize high-volume plastic processes and improve quality, productivity, and cost.

Roles & Responsibilities:

• Serve as the primary technical resource for complex molding challenges and leads initiatives to improve safety, quality, productivity, and manufacturing cost.
• Collaborate with Tooling, Engineering, Quality, Maintenance, and Production while mentoring technical personnel and establishing consistent molding practices
• Lead the development, validation, and optimization of injection molding processes for new and existing products.
• Establish molding process standards, validated operating windows, and process control strategies for consistent quality and performance.
• Serve as the technical escalation point for complex molding defects, recurring process issues, and production instability.
• Lead mold trials, process qualifications, and production validations; coordinate first article inspections with Quality.
• Lead process engineering for new mold launches, engineering changes, and startups, including readiness reviews and handoff to Production.
• Apply scientific molding, Design of Experiments (DOE), and statistical analysis to develop robust, repeatable processes.
• Partner with the Tooling Engineer to improve mold performance, cooling, venting, gating, and reliability.
• Lead improvement projects targeting scrap, cycle time, throughput, downtime, and Overall Equipment Effectiveness (OEE).
• Analyze process data, prioritize improvement opportunities, and verify sustained results.
• Lead cross-functional root cause investigations and ensure corrective and preventive actions address underlying causes.
• Establish and maintain process documentation, standard operating procedures, setup sheets, and specifications.
• Evaluate molding equipment, automation, robotics, and auxiliary systems; support capital proposals, specifications, installation, and qualification.
• Provide technical leadership and mentoring to Process Engineers, Process Technicians, Team Leaders, and production personnel.
• Develop technical training and consistent setup, troubleshooting, and process control practices across shifts.
• Partner with Quality to investigate customer concerns and verify corrective action effectiveness.
• Ensure process changes follow change-control procedures, safety policies, quality standards, applicable ISO requirements, and customer specifications.
• Approve molding parameters, operating windows, and process validation documentation within assigned authority.
• Establish technical standards for molding setup, monitoring, troubleshooting, and optimization.
• Stop production when process conditions compromise product quality or safety.
• Lead technical investigations and direct process-related corrective actions.
• Review and recommend tooling modifications, equipment upgrades, automation, and capital improvements.
• Recommend technical priorities and project resources to the Molding Manager.
• Provide technical direction for molding improvement projects and production launches.

Qualifications:

• Bachelor's degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related engineering discipline required.
• Minimum of seven (7) years of progressive injection molding process engineering experience, including demonstrated technical leadership.
• Demonstrated success independently resolving complex molding issues and sustaining quality, productivity, and cost improvements.
• Significant experience with scientific molding, process validation, and mold qualification.
• Experience leading new mold launches and product introductions from trials through stable production.
• Experience leading cross-functional improvement projects and managing multiple technical priorities.
• Experience mentoring engineers, technicians, and production personnel.
• Advanced knowledge of injection molding, thermoplastic materials, and high-volume plastics manufacturing.
• Expert understanding and practical application of scientific molding principles.
• Strong knowledge of mold design, tooling, resin processing, cooling systems, venting, and gating.
• Advanced troubleshooting and root cause analysis skills for complex molding problems.
• Proficiency in process validation, DOE, statistical process control (SPC), and process capability analysis.
• Knowledge of automation systems, robotics, and auxiliary molding equipment.
• Ability to translate process data into prioritized improvements and measurable manufacturing results.
• Strong project management skills, including planning, coordination, risk assessment, and follow-through.
• Ability to lead cross-functional teams and mentor technical personnel.
• Proficiency with Microsoft Office, ERP systems, and engineering documentation software.
• Excellent communication skills and sound technical judgment.
• High degree of integrity, professionalism, confidentiality, and accountability.
• RJG Scientific Molding certification preferred.
• Advanced scientific molding or Master Molder training preferred.
• Lean Six Sigma Green Belt or higher preferred.
• Experience evaluating molding equipment, automation, or capital improvement projects preferred.

Training Requirements:

• Successful completion of company onboarding requirements.
• Annual ethics and compliance training.
• Maintain applicable engineering, safety, and quality certifications.
• Complete advanced technical and leadership training as required for the position.
• Complete additional training as assigned based on equipment, process changes, customer requirements, or business needs.

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Flexible spending account
• Health insurance
• Life insurance
• Vision insurance