Process Manufacturing Engineer

Position Summary

The Process Manufacturing Engineer is responsible for developing, implementing, and sustaining robust, repeatable injection molding processes that support the successful transition of new products and tooling into production.

This position serves as a key technical connection between the NPI Team, NPI Tooling Engineers, Manufacturing Engineering, Quality Engineering, and Manufacturing Operations. The Process Manufacturing Engineer works closely with these teams from initial tooling trials through production launch to ensure that tooling, equipment, process parameters, and manufacturing methods come together to produce consistent, high-quality parts in a production environment.

This is a hands-on engineering role. The successful candidate will spend time on the manufacturing floor working directly with tooling, molding equipment, process parameters, and production teams. The role requires the ability to move beyond developing a process that works during a trial and establish a process that is stable, repeatable, documented, and capable of being consistently executed by Manufacturing.

The Process Manufacturing Engineer will also support ongoing production by troubleshooting process issues, improving process capability, reducing variation and scrap, and partnering with Manufacturing and Quality to continuously improve the performance of the injection molding operation.

Duties and Responsibilities

NPI & Process Development

• Partner with the NPI Team and NPI Tooling Engineers during the development and introduction of new injection molding tools and products.
• Work closely with Manufacturing Engineering and Quality Engineering to develop manufacturing processes that meet product, quality, and production requirements.
• Participate in tooling reviews, mold trials, sampling activities, and process development trials.
• Establish molding process parameters and operating conditions required to consistently produce conforming product.
• Evaluate tooling, equipment, materials, and process conditions during development to identify potential manufacturing risks and opportunities.
• Work collaboratively with NPI and Tooling Engineering to identify and resolve issues that may affect manufacturability, process capability, cycle time, or production readiness.
• Support the transition of new tooling and processes from NPI into production.
• Ensure processes developed during NPI can be effectively transferred to and executed by the Manufacturing Team.

Production Process Development

• Develop and optimize injection molding processes to achieve stable, repeatable, and capable production.
• Establish appropriate process parameters, setup conditions, operating windows, and process controls.
• Conduct hands-on process trials and adjustments on injection molding equipment.
• Evaluate process performance using production and quality data to identify sources of variation and opportunities for improvement.
• Work directly with Manufacturing personnel to understand process challenges and develop practical solutions.
• Troubleshoot molding, tooling, equipment, material, and process-related issues.
• Partner with Quality Engineering to investigate process-related defects, determine root cause, and implement sustainable corrective actions.
• Support the development and implementation of standardized work and process documentation.

Tooling & Manufacturing Partnership

• Work directly with NPI Tooling Engineers to understand tooling design, functionality, and performance as it relates to the molding process.
• Participate in mold setup, trials, troubleshooting, and process optimization activities.
• Provide technical input regarding tooling performance, process requirements, and production considerations.
• Collaborate with Manufacturing and Tooling resources to resolve recurring mold and process issues.
• Help identify opportunities to improve mold performance, process stability, cycle time, and overall manufacturing efficiency.
• Maintain a strong hands-on presence in the manufacturing environment and build effective working relationships with operators, technicians, engineers, and leadership.

Production Launch & Process Sustainment

• Support production launch activities to ensure new processes are ready for routine manufacturing.
• Work with Manufacturing to confirm processes are practical, repeatable, and capable of being executed consistently.
• Monitor early production performance and make appropriate process improvements following launch.
• Support process qualification and validation activities as required.
• Develop and maintain process documentation, setup parameters, work instructions, and other manufacturing requirements.
• Provide technical support for ongoing production issues and process improvements.
• Ensure process changes are appropriately evaluated, documented, and implemented in accordance with Aptyx quality system and change control requirements.

Continuous Improvement

• Identify and implement opportunities to improve process capability, quality, productivity, cycle time, and cost.
• Use data and structured problem-solving methods to reduce scrap, variation, downtime, and recurring process issues.
• Identify opportunities to improve process repeatability and standardization across production.
• Partner with Manufacturing, Quality, Tooling, and Engineering to implement sustainable improvements.
• Support a culture of continuous improvement and operational excellence within the Torrington Injection Molding operation.

Qualifications

Education & Experience

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Plastics Engineering, or a related engineering discipline preferred.
• Experience developing and optimizing injection molding processes in a manufacturing environment.
• Hands-on experience with injection molding processes, tooling, mold trials, and process troubleshooting.
• Experience supporting new product introduction, tooling development, process development, or production launch preferred.
• Experience working cross-functionally with Manufacturing, Tooling, Quality, and Engineering teams.
• Equivalent combinations of education, technical training, and relevant manufacturing experience may be considered.

Technical Competencies

Injection Molding Process Development

• Strong understanding of injection molding processes and process variables.
• Ability to establish and optimize molding parameters.
• Ability to develop stable and repeatable process windows.
• Understanding of factors that influence part quality, cycle time, and process variation.

Tooling & Equipment

• Understanding of injection molding tooling and its relationship to process performance.
• Ability to participate in mold trials, tooling troubleshooting, and process optimization.
• Ability to identify tooling or equipment conditions that may affect production performance.

Manufacturing & NPI

• Ability to take a process from development and trial through production launch.
• Understanding of production requirements and the importance of designing processes that are practical for Manufacturing to execute.
• Ability to translate development activities into standardized production processes.

Problem Solving

• Strong root-cause analysis and troubleshooting skills.
• Ability to use process and quality data to identify trends and sources of variation.
• Ability to develop corrective actions that address the underlying cause rather than temporary fixes.

Process Standardization

• Ability to document processes, parameters, setup requirements, and standard work.
• Strong focus on repeatability, consistency, and process control.
• Ability to establish processes that can be reliably executed across shifts and operators.

Aptyx Core Competencies

Make It Happen

• Takes ownership of process development and manufacturing challenges.
• Works hands-on to move processes from development through production.
• Follows through on issues and improvements until sustainable solutions are implemented.

Collaborative Partnership

• Builds strong working relationships with NPI, Tooling, Manufacturing, Quality, and Engineering.
• Communicates effectively across technical and operational teams.
• Works collaboratively to balance product, quality, tooling, process, and production requirements.

Commitment to Quality

• Develops processes that consistently produce product meeting defined requirements.
• Uses disciplined process development and problem-solving practices.
• Maintains strong attention to process control, documentation, and quality system requirements.

Integrity in Action

• Uses sound technical judgment and data to make process decisions.
• Follows established procedures, specifications, and change control requirements.
• Takes accountability for the effectiveness and sustainability of implemented processes.

Growth Mindset

• Continuously looks for opportunities to improve process capability and manufacturing performance.
• Learns from process trials, production results, and technical challenges.
• Shares knowledge and helps build technical capability within the Manufacturing organization.

Key Working Relationships

Internal: NPI Team, NPI Tooling Engineers, Manufacturing Engineering, Quality Engineering, Manufacturing Operations, Maintenance, and site leadership.

External: Tooling suppliers, equipment suppliers, and other technical resources as required.

What Success Looks Like

Success in this role means that new tooling and products do not simply make a good part during an NPI trial - they become stable, repeatable production processes that Manufacturing can consistently execute.

The successful Process Manufacturing Engineer will:

• Establish robust molding processes that consistently meet quality requirements.
• Successfully transition new tooling and processes from NPI into production.
• Build strong partnerships with Tooling, NPI, Quality, Manufacturing Engineering, and Operations.
• Reduce process variation, scrap, downtime, and recurring manufacturing issues.
• Develop clear and sustainable process documentation and standard work.
• Become a trusted technical resource for the Torrington Injection Molding operation.

Process