Senior Process Engineer

The Senior Process Engineer is responsible for developing, optimizing, and troubleshooting injection molding processes to ensure efficient, high-quality, and cost-effective production. This role requires working with cross-functional teams to improve process stability, reduce waste, and drive continuous improvement initiatives. The engineer will play a key role in tooling qualifications, process standardization, and developing best practices in molding operations.

Responsibilities

Develop, implement, and optimize injection molding processes to improve efficiency, quality, and cycle times; Troubleshoot and resolve molding defects, tooling issues, and process variations using root cause analysis techniques; Utilize scientific molding principles and process optimizations tools including Design of Experiments to establish capable and consistent molding processes; Assist with new production equipment installation and qualification, providing feedback on suitability, performance and reliability; Lead process development for tool qualifications and test runs supporting both new product introductions and capacity tooling; Work closely with tooling engineers, maintenance teams, and production staff to enhance mold performance and longevity; Standardize process documentation, including work instructions, SOPs, and process sheets; Implement continuous improvement projects focused on cycle time reduction, scrap reduction, and process efficiency; Research and recommend new molding technologies, automation, and auxiliary equipment to enhance production capabilities; Provide technical leadership and training to engineers, technicians, and production personnel; Ensure compliance with all quality standards and company policies; Actively represent the processing capability during mold design reviews and DFM evaluations to insure processing consideration are included in the tooling design cycle; Provide on-site support for tooling trials and evaluations at tooling vendors; Recommend resins and additive packages to support product performance requirements and manufacturing needs while insuring all material-based safety protocols and PPE needs are understood and met.

Requirements

Bachelor’s degree in Mechanical engineering, Plastics engineering, or a related field; 7+ years of experience in injection molding process development, tooling, and manufacturing with a focus on tight tolerance, precision injection molding; Strong understanding of polymer materials, mold construction, and processing parameters with a focus on engineering grade resins including PEI, PBT, and PC/ABS; Expertise in scientific molding techniques, mold flow analysis, and process validation methodologies; Hands-on experience with injection molding machines, robotics, and automation systems; Familiarity with lean manufacturing principles, Six Sigma methodologies (Green/Black Belt preferred), and SPC; Proficiency in troubleshooting molding defects such as flash, short shots, burns, warpage, and splay; Strong analytical, problem-solving, and project management skills; Demonstrated ability to make data-driven decisions using data analysis tools and techniques; Effective communication and teamwork abilities for cross-functional collaboration.

Nice to have

Formal Master Molder or similar training RJG, AIM, etc.; Six Sigma Green/Black Belt preferred

Benefits

Competitive base salary with performance-based bonus potential; 4 weeks of PTO to relax and recharge; Health, dental, and vision plans to support you and your family; 401(k) retirement savings plan with employer match and planning resources; A collaborative, team-based culture focused on innovation and quality; Paid holidays and employee recognition programs; Opportunities to work with advanced molding technologies and infrastructure systems; STEM outreach and community engagement initiatives