Senior engineer - process

Responsibilities

Collaborate with product development teams to design and optimize plastic components for manufacturability, performance, and cost-effectiveness; Apply principles of DFM (Design for Manufacturability) to ensure robust and efficient production; Understand CAD software to review 3D models and 2D drawings of plastic parts and assemblies; Work closely with toolmakers and suppliers to define, design, and procure injection molds; Review and approve mold designs, ensuring adherence to specifications, quality standards, and production requirements; Lead the development and procurement of prototype tooling, evaluating different tooling approaches for early-stage product validation; Identify and implement improvements to existing tooling for enhanced performance, longevity, and reduced cycle times; Oversee set up, operation, and troubleshooting of injection molding presses to achieve optimal part quality and production efficiency; Develop and refine molding parameters (temperatures, pressures, cycle times, etc.) for various plastic resins; Conduct root cause analysis for molding defects and implement corrective actions; Perform process validation and qualification activities; Utilize mold flow simulation software (e.g., Moldflow, SolidWorks Plastics) to predict and optimize material flow, cooling, warpage, and other molding phenomena; Interpret simulation results to guide part and tool design decisions, minimizing potential molding issues; Oversee and manage external injection molding suppliers to ensure consistent quality, on-time delivery, and adherence to specifications; Conduct supplier audits, assess capabilities, and drive continuous improvement initiatives with suppliers; Act as the primary technical liaison with molding suppliers, resolving technical issues and ensuring optimal performance; Evaluate supplier performance metrics and implement strategies to enhance overall supplier relationships and output; Research, evaluate, and recommend appropriate plastic resins and compounds based on product requirements, performance specifications, environmental considerations, and cost constraints; Possess a deep understanding of the properties, processing characteristics, and applications of various thermoplastic and thermoset materials; Conduct material testing and characterization to validate performance and ensure suitability for specific applications; Develop and implement quality control plans for plastic components; Participate in FMEA (Failure Mode and Effects Analysis) and other quality improvement initiatives; Identify and implement opportunities for process optimization, waste reduction, and cost savings; Provide technical expertise and support to manufacturing, quality, and sales teams; Communicate effectively with internal and external stakeholders, including suppliers and customers; Mentor junior engineers and technicians on plastics engineering principles

Requirements

Bachelor of Science in Mechanical Engineering (BSME) required; 10+ years of hands-on experience in the plastics industry, specifically with injection molding processes; Proficiency in operating and troubleshooting injection molding presses; Strong understanding of injection mold tooling design principles and construction, including prototype tooling methodologies; Proven experience with mold flow simulation software (e.g., Moldflow, SolidWorks Plastics) and the ability to interpret results; Familiar with CAD software (e.g., SolidWorks, Creo, AutoCAD) for 3D modeling and 2D drafting; Solid understanding of plastic material properties, processing characteristics, and selection criteria; Ability to read and interpret technical drawings and specifications (GD&T knowledge preferred); Excellent problem-solving, analytical, and critical thinking skills; Strong communication (written and verbal) and interpersonal skills; Self-motivated, proactive, and able to work independently as well as in a team environment; Ability to thrive in a fast-paced, dynamic manufacturing environment; The ability to communicate fluently in English is essential; Willingness and ability to travel internationally up to 30% of the time; Ability to communicate in Mandarin is required for travel to China; Requires flexibility in working hours to accommodate evening calls with US-based colleagues

Nice to have

Experience with other plastic manufacturing processes (e.g., extrusion, blow molding); Knowledge of automation and robotics in plastics manufacturing; Experience with statistical process control (SPC) and lean manufacturing principles