Sr. Process Engineer

Job Title

Sr. Process Engineer

Lincolnshire, IL

Imagine a company with technology leadership of over 160 years, yet it operates with the energy of a startup. Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission‑critical flow creation and life science technologies—from compressors to precision handling of liquids, gases, and powers—to increase industrial productivity, efficiency, and sustainability.

Supported by over 80+ brands, our products are used in various end‑markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more.

Across the globe, we’re driving growth with an entrepreneurial spirit and ownership mindset. Learn more at  and join us to own your future.

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, 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 by improving capability (Cp/Cpk) and reducing 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, 8‑D, 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) operate within validated performance parameters.
• Drive improvements in cycle time optimization, scrap and rework reduction, OEE, material usage and yield optimization, and 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 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.

• Cooperate and demonstrate professional conduct with coworkers, staff and managers.
• Communicate effectively with Flexan’s employees and management, and demonstrate all Flexan corporate values: quality, accountability, respect, innovation, integrity, open and honest communications, teamwork, and customer focus.

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