Process Engineer - Costa Mesa, California,

Position: Process Engineer - Costa Mesa, California, United States
Location(s):
Costa Mesa, California Company:
Phillips Medisize Career Field:
Engineering Job Number: 196288

Apply:  Job As a Process Engineer based in Costa Mesa, California, you will develop, validate, improve, and sustain manufacturing processes for injection-molded and over molded medical-device and cable-assembly products. You will serve as the technical owner for molding and over molding processes from concept through production release, helping deliver safe, capable, efficient, and compliant manufacturing operations.

This role provides technical leadership for new product introductions, process transfers, tooling development, scientific molding studies, process validation, and continuous improvement. The primary focus is thermoplastic injection molding and component or cable over molding.

Our Team You will collaborate with manufacturing operations, quality, project engineering, tooling and equipment suppliers, customers, technicians, and other cross-functional partners. The team supports new-product development and existing production by translating technical challenges into practical, production-ready manufacturing solutions.

What You Will Do Develop and optimize thermoplastic injection-molding and overmolding processes using scientific molding principles, design of experiments, capability studies, and data-driven analysis

Lead molding process development for new product introductions, product transfers, prototype builds, validation activities, production launches, and sustaining products

Establish robust process windows and resolve molding defects, including flash, short shots, sink, voids, burns, flow lines, delamination, cosmetic issues, and overmold bonding failures

Support mold design reviews and design-for-manufacturability activities, and coordinate mold fabrication, qualification, debugging, acceptance, and production readiness

Specify and qualify molding machines, fixtures, automation, auxiliary equipment, material-handling systems, and inspection equipment

Develop and execute engineering and validation studies, including equipment qualification and installation qualification, operational qualification, and performance qualification activities

Author and review engineering protocols, validation protocols, final reports, process documentation, risk assessments, process failure mode and effects analyses, control plans, and process-change assessments

Lead root-cause analysis, corrective actions, and improvements related to scrap, defects, cycle time, overall equipment effectiveness, yield, capacity, cost, and recurring process disruptions

Train technicians, operators, and engineering personnel on new or revised processes and monitor sustained process capability after implementation

Who You Are (Basic Qualifications)
Bachelor’s degree in mechanical engineering, manufacturing engineering, plastics engineering, industrial engineering, or another engineering discipline5+ years of manufacturing or process engineering experience3+ years of hands-on thermoplastic injection-molding or over molding experience

Experience with scientific molding, thermoplastic material behavior, material drying, process-window development, design of experiments, capability analysis, root-cause analysis, or process validation

Experience developing or sustaining manufacturing processes in a production environment

What Will Put You Ahead Experience in medical-device or another regulated manufacturing environment

Experience with cable-assembly molding and overmolding

Experience with silicone molding or silicone overmolding

Experience with insert molding, multi-shot molding, automation, robotics, or vision-inspection systems

Experience with installation qualification, operational qualification, and performance qualification validation activities

Experience with Solid Works or equivalent computer-aided design software

Experience applying Lean or Six Sigma methods to improve scrap, cycle time, yield, capacity, or manufacturing cost

This role is not eligible for VISA Sponsorship. For this role, we anticipate paying $105,000 - $120,000 per year. This role is eligible for variable pay, issued as a monetary bonus or in another form.

At Koch companies, we are entrepreneurs. This means we openly challenge the status quo, find new ways to create value and get rewarded for our individual contributions. Any compensation range provided for a role is an estimate determined by available market data. The actual amount may be higher or lower than the range provided…