Process Engineer

Plastic Injection Molding Process Engineer

The Plastic Injection Molding Process Engineer is responsible for developing, optimizing, validating, and sustaining injection molding processes to ensure safe, efficient, and high-quality production. This position works closely with Operations, Quality, Tooling, Maintenance, Engineering, and Program Management teams to improve manufacturing performance, reduce costs, support new product launches, and drive continuous improvement initiatives throughout the molding operation.

Reports To: Operations Manager

Essential Duties and Responsibilities

• Develop, establish, validate, and document robust injection molding processes for new and existing products.
• Lead process development activities, including mold trials, process studies, capability analysis, and production validations.
• Analyze molding processes and implement improvements to increase productivity, quality, and overall equipment effectiveness (OEE).
• Troubleshoot molding defects, including flash, short shots, sink marks, burn marks, splay, warpage, dimensional variation, and cosmetic defects.
• Utilize scientific molding principles and data-driven methodologies to establish and maintain process controls.
• Conduct root cause investigations and implement corrective and preventive actions for process-related issues.
• Support new product launches, process qualifications, mold validations, and production ramp-ups.
• Develop and maintain standard process sheets, work instructions, validation documentation, and engineering records.
• Collaborate with Quality to establish process capability requirements and improve product consistency.
• Identify opportunities to reduce cycle times, scrap, downtime, material consumption, and manufacturing costs.
• Evaluate and implement process improvements involving automation, robotics, vision systems, and auxiliary equipment.
• Partner with Tooling and Maintenance teams to improve mold performance, reliability, and preventive maintenance programs.
• Lead continuous improvement projects utilizing problem-solving methodologies.
• Support production teams by providing technical guidance and training on molding processes and best practices.
• Participate in customer audits, quality investigations, and corrective action activities as required.
• Ensure compliance with safety, environmental, and company policies.

Required Qualifications

• Bachelor's degree in Engineering, Plastics Engineering, Manufacturing Engineering, Mechanical Engineering, or a related technical field.
• Minimum of 3 to 7 years of experience in plastic injection molding process engineering or advanced process development.
• Strong knowledge of injection molding equipment, molds, tooling, and resin processing.
• Experience developing and validating molding processes in a manufacturing environment.
• Knowledge of scientific molding principles and process optimization techniques.
• Experience with root cause analysis, statistical methods, and process capability analysis.
• Ability to read and interpret engineering drawings, GD&T, specifications, and quality standards.
• Proficiency with Microsoft Office and manufacturing software systems.
• Excellent analytical, organizational, and problem-solving skills.
• Strong communication and project management abilities.

Preferred Qualifications

• Bachelor's degree in Plastics Engineering.
• RJG Master Molder Certification or equivalent Scientific Molding certification.
• Experience with automation systems, robotics, and machine vision technologies.
• Experience in automotive, medical, consumer products, or other high-volume injection molding environments.
• Knowledge of DOE (Design of Experiments), Moldflow analysis, and process capability studies.

Knowledge, Skills, and Abilities

• Injection molding process development and optimization.
• Scientific molding and process validation methodologies.
• Plastic resin behavior, material drying, and material handling systems.
• Statistical Process Control (SPC) and process capability analysis.
• Root cause analysis and corrective action implementation.
• Continuous improvement methodologies.
• Project leadership and cross-functional collaboration.
• Automation and manufacturing technology integration.
• Strong technical writing and documentation skills.
• Excellent verbal and written communication skills.

Physical Requirements

• Ability to stand, walk, and move throughout the manufacturing facility for extended periods.
• Ability to occasionally lift up to 35 pounds.
• Ability to inspect molds, machines, and manufacturing equipment.
• Frequent reaching, bending, and interaction with manufacturing equipment.
• Ability to safely wear required personal protective equipment (PPE).

Work Environment

• Manufacturing environment with exposure to moving machinery, noise, heat, and plastic processing equipment.
• Frequent interaction with production, tooling, engineering, and maintenance personnel.
• Occasional travel may be required to suppliers, customers, or other company facilities.
• May require schedule flexibility to support process trials, launch activities, and critical production needs.

Key Performance Indicators (KPIs)

• Scrap Reduction
• Overall Equipment Effectiveness (OEE)
• Cycle Time Reduction
• First Pass Yield (FPY)
• Process Capability (Cp/Cpk)
• Cost Reduction Achievement
• Downtime Reduction
• New Product Launch Success
• Process Validation Completion
• Continuous Improvement Project Results
• Customer Quality Performance
• Safety Performance

Success Factors

• Establishes repeatable and robust molding processes.
• Reduces process variation and manufacturing costs.
• Improves productivity and equipment utilization.
• Successfully supports new product introductions and transfers.
• Drives data-based decision-making and continuous improvement.
• Acts as the technical expert for injection molding process performance and optimization.