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

Ingersoll Rand has dedicated itself to making life better for employees, customers, shareholders, and the planet. We produce innovative and mission‑critical flow‑creation and life‑science technologies for various end‑markets, including life sciences, food and beverage, clean energy, industrial manufacturing, and infrastructure.

The Process Engineer is responsible for developing, optimizing, and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR). The role focuses on driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues, and ensuring stable manufacturing performance across all molding work centers. Collaboration with Tooling, Production, Quality, NPI, and Maintenance teams is essential for successful product launches and efficient manufacturing processes.

• Develop, validate, and optimize molding processes for LSR injection, HCR injection, compression, and transfer molding, including 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, flash prevention parameters, and 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.
• Provide daily technical support to address 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 robust corrective and preventative 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 (presses, injection units, dosing systems, thermolators) operates within validated performance parameters and provide feedback to improve mold robustness, reduce tool wear and minimize flash.
• Drive improvements in cycle time optimization, scrap and rework reduction, OEE (availability, performance, quality), 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, and cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks, and improvement projects.
• Maintain cooperation and professional conduct with coworkers, staff, and managers, demonstrating values such as quality, accountability, respect, innovation, integrity, open communication, teamwork, and customer focus.

• Bachelor’s degree in Mechanical, Manufacturing, Materials, Plastics, or Polymer Engineering.
• 5+ years of direct experience in silicone and/or rubber molding, with strong understanding of LSR and HCR injection, compression, and transfer molding, cure cycles, post‑cure, and material behavior.
• Experience with tool design elements (cavitation, gating, venting, steel types).
• Proficiency using DOE, SPC, and other statistical tools for process…