Sr. Process Engineer

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.

Sr. Process Engineer

Lincolnshire, IL

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.

• 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 optimize process capability (Cp/Cpk) and reduce variation.
• Establish and maintain standardized process parameter sheets, recipes and work instructions.
• Provide daily technical support to address molding issues such as flash, short shots, cure variations, knit lines and voids, sticking and ejection problems, inconsistent shrink, durometer and dimensional stability.
• Lead structured root cause analysis (5 why, 8D, fishbone) and implement robust corrective and preventive actions.
• Train operators and technicians in molding best practices and process discipline.
• Partner with Tooling Engineer on gate/vent design, cold runner or valve‑gate LSR systems, mold thermal management, vent maintenance, mold qualification and production readiness.
• Support maintenance to ensure equipment operates within validated performance parameters and provide feedback to improve mold robustness and minimize flash related issues.
• Drive continuous improvement in cycle time, 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.
• 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.
• Demonstrate professional conduct, cooperation, and company values:
  Quality, Accountability, Respect, Innovation, Integrity, Open & honest communications, Teamwork, and Customer focus.

• Bachelor’s degree in an Engineering discipline (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 experience (cavitation, gating, venting, steel types).
• 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.

• Experience with Solid Works 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 ISO
  13485 and clean room procedures would be beneficial.

Onsite.

$100-$125k.

Our comprehensive benefits package includes health care options such as medical and prescription plans, dental and vision coverage, wellness programs, life insurance, a robust 401(k) plan, paid time off and employee stock grants. These benefits are our commitment to you, so you can be your best at work and beyond.