Process Engineer

Job Description

Job Description

Want to be part of something special? We're Filling Important Jobs!Join an industry leader and innovator looking for people who want to make a difference.Hoffer Plastics is hiring for " Process Engineer", "1st shift". Starting Pay $85k - $115K (based on experience) ESSENTIAL RESPONSIBILITIES: NEW TOOL REVIEWParticipate in the review of new molds, transferred molds, engineering changes, and new product launches to ensure the tooling and manufacturing process are designed for successful production. Participate in new product and tooling review meetings throughout the development process. Review part and mold designs from an injection molding and Design for Manufacturing (DFM) perspective. Identify potential processing, tooling, material, quality, automation, and production risks before the mold reaches production. Review proposed gate locations, runner systems, hot runner systems, cooling requirements, venting, ejection, cavity layout, and other mold features that can affect process capability. Review available mold-flow or simulation information and provide processing input when appropriate. Evaluate projected cavity pressures, clamp-tonnage requirements, shot-size requirements, recovery requirements, expected cycle time, and other machine requirements. Determine whether the proposed mold is compatible with available injection molding machines and identify required auxiliary equipment. Review mold water requirements and verify that adequate water circuits, flow, pressure, and temperature control are available. Participate in tool trials and mold samplings as required and document processing or tooling concerns for the project team. Work with Engineering, Tooling, Quality, and Manufacturing to resolve identified concerns before production launch whenever possible. Support domestic and international tool shops as required during mold build, sampling, and debugging. PROCESS DEVELOPMENTDevelop a robust, repeatable, and documented injection molding process that can be successfully transferred to normal production. Coordinate and participate in mold samplings and process-development activities using scientific and decoupled molding principles. Establish a repeatable molding process based on actual process data rather than machine settings alone. Perform appropriate process-development studies to establish the molding window and understand the response of the process to normal manufacturing variation. Evaluate fill speed, transfer position, cavity balance, injection pressure, hold pressure, hold time, cooling time, melt temperature, mold temperature, clamp tonnage, recovery, and other critical process variables. Verify that the process operates within the capabilities of the selected injection molding machine and establish upper and lower limits for critical variables where appropriate. Verify that the developed process produces acceptable product under normal production conditions and identify critical process parameters and potential failure points. Work with Quality to verify dimensional and functional product requirements during process development. Develop and maintain clear process documentation covering mold setup, machine requirements, process settings and limits, material and drying requirements, auxiliary equipment, water, automation, and special instructions. Assist with the transition of newly developed processes from Engineering into Manufacturing and support the initial production startup. Verify that the developed process can be duplicated by plant personnel and train appropriate personnel on new processes and special processing requirements. PRODUCTION SUPPORTProvide technical support to Manufacturing when production problems cannot be resolved through normal plant troubleshooting activities. Support manufacturing personnel with difficult, chronic, or recurring injection molding problems. Troubleshoot issues involving the process, machine, mold, material, hot runner system, temperature-control equipment, dryers, material handling, robots, automation, and other auxiliary equipment. Use a structured troubleshooting approach to identify the actual cause of production problems and separate process-related issues from tooling, equipment, material, and quality issues. Review actual process data and machine performance before recommending changes. Ensure process changes remain within the established process window whenever possible and avoid using processing changes to compensate for tooling or equipment conditions that should be corrected. Work with Plant Managers, Process Technicians, Maintenance, Tooling, Engineering, and Quality to resolve production issues. Assist plants with difficult mold startups, process transfers, and recurring production problems. Verify corrective actions are effective, document significant process changes, and update process documentation when approved permanent changes are made. Provide technical coaching and training to processing personnel as needed. SCRAP REDUCTION AND CONTINUOUS IMPROVEMENTActively identify and pursue opportunities to reduce scrap, improve productivity, improve process capability, and eliminate recurring manufacturing problems. Review plant scrap and defect data to identify the largest processing-related opportunities and prioritize improvement projects based on measurable business impact. Work with Manufacturing and Quality to identify the true root causes of recurring defects using data-driven problem-solving rather than trial-and-error processing. Evaluate process capability and identify processes operating near or outside their established processing window. Identify molds or processes that require redevelopment or optimization and perform structured studies to determine the relationship between process variables and product quality. Lead or participate in corrective-action activities involving molding processes. Develop corrective actions that address root cause rather than simply adjusting machine settings to temporarily eliminate symptoms. Identify opportunities to reduce scrap, startup scrap, downtime, cycle time, material usage, colorant usage, energy consumption, and unplanned process adjustments. Work with Tooling and Maintenance when process data indicates mechanical or tooling conditions are contributing to scrap. Verify improvements through measurable before-and-after results and standardize successful improvements across similar molds, machines, or facilities when appropriate. Maintain documentation of significant improvements and lessons learned. TECHNOLOGY ADVANCEMENT AND PROCESS DEVELOPMENT STRATEGYContinuously advance the company's injection molding knowledge, process-development methods, and technical capabilities so new-tool qualification and launch strategies improve as technology and industry knowledge evolve. Stay current with advancements in injection molding technology, scientific molding, process-development strategies, mold technology, machine controls, process monitoring, automation, materials, and auxiliary equipment. Continuously evaluate industry best practices and determine whether they can improve the company's process-development methodology and new-tool launch process. Research new process-development studies and techniques that can provide a better understanding of mold, machine, material, and process capability before a tool is released to production. Identify opportunities to expand or improve standard process-development tests based on lessons learned from tool launches, production issues, scrap investigations, and industry advancements. Develop, test, and validate new process-development studies before incorporating them into the company's standard tool-launch process. Regularly review existing process-development tests to determine whether additional data, calculations, acceptance criteria, or testing methods could improve their effectiveness. Use mold sampling to develop a deeper understanding of mold capability, machine capability, material behavior, process sensitivity, cavity-to-cavity variation, cooling performance, pressure requirements, flow characteristics, process repeatability, process-window size, and potential production risks. Look beyond whether a mold can simply produce an acceptable part and determine how robust the overall molding system will be under normal production variation. Evaluate new methods for testing machine capability and determining whether a molding machine is appropriate for a particular mold and process.PHYSICAL REQUIREMENTS: Incumbent will: usually stand/walk most of the shift. frequently bend at waist, twist, kneel/crouch, climb ladders, and climb up on machinery with proper fall protection. occasionally push, pull, and lift up to 75 lbs. or more. occasionally lift above waist and/or shoulder up to 75 lbs. and over. sometimes perform hand/wrist/finger movements and foot movements for pedal controls on forklift. occasionally perform keyboarding and squeezing movements. frequently be exposed to odors, dust, oil/grease, heat, noise, and operating machinery. QUALIFICATIONS: Five or more years of direct injection molding processing experience or equivalent applicable experience. Strong understanding of scientific molding and decoupled molding principles. Demonstrated ability to develop and troubleshoot injection molding processes. Strong mechanical aptitude and ability to interpret molding-machine and process data. Ability to systematically troubleshoot mold, machine, material, process, and auxiliary-equipment problems. Strong analytical, problem-solving, verbal, written, and technical documentation skills. Ability to work effectively with Engineering, Manufacturing, Quality, Tooling, Maintenance, suppliers, and management. Computer proficient and able to use data-analysis and process-documentation tools. Ability to travel to manufacturing facilities, suppliers, and tool shops as required. Associate degree in Engineering, Engineering Technology, Plastics, Manufacturing, Mechanical, or related technical field preferred; Bachelor's degree in Engineering or related discipline preferred. Equivalent direct injection molding experience may be considered in place of formal education. RJG, AIM, Paulson, or equivalent advanced injection molding training strongly preferred.   Benefits:Blue Cross Blue Shield Medical, Dental and VSP Vision InsuranceHoffer Plastics matches .50 per $1.00 dollar contributed each payroll period up to 6% plus a Safe Harbor contribution of an amount equal to 3% of employee's annual eligible earningsPaid Life Insurance in the amount of 1.5 times basic annual salaryShort term and Long-term Disability2 Weeks Paid Vacation and up to 5 Days of Illinois Paid Leave.9 Paid HolidaysReimbursements (Tuition, Prescription Safety Glasses, Steel Toe Shoe, and Fitness)Join an established, growing third generation U.S. company that goes "All In" for people, plastics and purpose.Hoffer Plastics Corporation: There's a part of us in Every Piece. Plastics is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, race, color, religion, sex, sexual orientation, gender identity, national origin, disability or veteran status.