Sr. Process Engineer

Sr. Process Engineer Location: Lincolnshire, IL Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances. About Us Imagine a company with technology leadership of over 160 years, yet it operates with the energy of a startup. Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission-critical flow creation and life science technologies - from compressors to precision handling of liquids, gasses, and powers - to increase industrial productivity, efficiency, and sustainability. Supported by over 80+ brands, our products are used in various end-markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more. Across the globe, we're driving growth with an entrepreneurial spirit and ownership mindset. Learn more at irco.com and join us to own your future. Job Overview The Process Engineer is responsible for the development, optimization and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The Process Engineer plays a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues and ensuring stable manufacturing performance across all molding work centers. The Process Engineer collaborates closely with the Tooling, Production, Quality, NPI and Maintenance teams to ensure successful product launches, consistent quality and efficient manufacturing processes. Responsibilities Process Development & Optimization: Develop, validate and optimize molding processes for LSR injection molding. HCR injection, compression and transfer molding. Multi-cavity, family molds and multi-shot configurations. Apply scientific molding techniques to establish injection/fill profiles, pack/hold strategies, cure and thermal control profiles, venting and flash prevention parameters. Perform process determination and DOE studies to improve capability (Cp/Cpk) and reduce variation. Establish and maintain standardized process parameter sheets, recipes and work instructions. Troubleshooting & Technical Support: Provide daily technical support for molding issues such as flash, short shots, cure variations, knit lines, voids, sticking, ejection problems, inconsistent shrink, durometer and dimensional stability. Lead structured root cause analysis (5 why, 8D, fishbone) and implement corrective and preventative actions. Train operators and technicians in molding best practices and process discipline. Tooling & Equipment Interaction: Partner with Tooling Engineer on gate/vent design, cold runner or valve-gate LSR systems, mold thermal management and vent maintenance, mold qualification and production readiness. Support maintenance to ensure equipment operates within validated performance parameters and provide feedback to improve mold robustness, reduce tool wear and minimize flash related issues. Continuous Improvement: Drive improvements in cycle time optimization, scrap and rework reduction, OEE, material usage and yield optimization. Participate in LEAN, Kaizen, 5S and efficiency projects. Use SPC, data analytics and process monitoring to identify and address instability. Cross-Functional Collaboration: Work with NPI Engineering on feasibility reviews, new mold trials and qualification, launch readiness and transfer to production. Support Quoting/Estimating with cycle time projections, material behavior expectations, cavitation/tooling strategy input. Communicate clearly with Production and Quality teams on process changes, risks and improvement projects. General Accountability: Cooperation and professional conduct with coworkers, staff, and managers. Demonstrate Flexan corporate values: Quality, Accountability, Respect, Innovation, Integrity, Open & honest communications, Teamwork, Customer focus. Requirements Bachelor's degree in Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer). 5+ years' direct experience in silicone and/or rubber molding, with strong understanding of LSR injection, HCR molding, compression and transfer molding, cure cycles, post-cure and material behavior, tool design elements. Experience using DOE, SPC and statistical tools for process improvement. Strong ability to interpret engineering drawings, GD&T, CAD models, customer and regulatory specifications. Demonstrated success in troubleshooting complex molding issues. Preferences Experience with SolidWorks or other 3D modelling software. Experience with mold flow analysis or ability to interpret results. Background in medical, automotive, aerospace or industrial silicone components. Experience supporting APQP, PPAP and customer audits. Experience with automation, vision inspection and deflashing/trimming technologies. Background with adhesion/bonding techniques, multi-shot molding and overmolding. RJG/Paulson certification or silicone-specific molding training. Familiarity with ISO13485 and clean room procedures. Travel & Work Arrangements/Requirements Onsite. Compensation The pay range for this role is $100,000 – $125,000. What We Offer At Ingersoll Rand, we embrace a culture of personal ownership and a comprehensive benefits package designed to empower you with the tools and support necessary to take charge of your health. Benefits include medical, prescription, dental and vision coverage; wellness programs; life insurance; a robust 401(k) plan; paid time off; employee stock grant and more. Ingersoll Rand is committed to workforce diversity reflective of our communities. We are an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances. #J-18808-Ljbffr