Process Engineer; Injection Molding

Overview

The Process Engineer is responsible for establishing, stabilizing, and sustaining robust injection molding processes that deliver safe, repeatable, and cost-effective production. This role owns process definition, control, troubleshooting, and continuous improvement across molding operations. The Process Engineer ensures processes are documented, controlled, trained, and enforced while partnering closely with Operations, Maintenance, Tooling, and Quality to reduce variability, scrap, and downtime.

This is a hands-on, manufacturing floor–focused role critical to plant performance and stability.

• Establish and validate scientific process windows for thermoplastic injection molding applications
• Define and maintain standard process settings, including melt temperature, injection velocity profiles, pack/hold pressure and time, cooling efficiency, and mold temperature control
• Apply material behavior principles such as viscosity, shrinkage, crystallization, and thermal sensitivity to process design
• Own process setup documentation, standard work, and controlled parameter limits
• Train and mentor production and technical teams to properly run and protect defined processes
• Lead root cause analysis of complex molding defects, including cosmetic, dimensional, and structural issues
• Correlate defects to material condition, mold design, and machine performance
• Utilize DOE, SPC, cavity pressure trends, and process data to implement permanent corrective actions
• Partner with Tooling and Maintenance to optimize mold cooling, venting, ejection, and part release
• Support mold trials, tooling changes, and new tool launches
• Ensure molds are technically capable of running within defined process windows
• Provide engineering input on mold wear components and preventive maintenance requirements
• Own molding-related process capability metrics (Cp/Cpk)
• Implement statistical process control on critical parameters and part characteristics
• Drive transition from inspection-based quality to process-controlled quality
• Support investigations related to scrap, quality holds, and customer complaints using data-driven analysis
• Support commissioning and validation of injection molding presses, robotics, automation, and auxiliary equipment
• Optimize cycle times without compromising part quality or mold life
• Ensure compliance with safety, environmental, and quality standards
• Support shift communication and coordination to maintain process consistency
• Perform other duties as assigned

Required:

• Bachelor’s degree in Engineering (Plastics, Mechanical, Manufacturing, or related discipline)
• 7+ years of hands-on injection molding process engineering experience
• Strong understanding of thermoplastic material behavior in molding applications
• Proven ability to analyze data and solve complex manufacturing problems

Preferred:

• Scientific molding certification (e.g., RJG Master Molder or equivalent)
• Experience with DOE, SPC, and continuous improvement methodologies
• Background in high-volume, multi-press manufacturing environments

• Deep knowledge of injection molding processes, mold design, materials, and process controls
• Strong analytical, troubleshooting, and root cause analysis skills
• Experience with statistical tools and quality improvement methodologies
• Ability to read and interpret technical drawings, specifications, and process data
• Strong communication skills and ability to work cross-functionally
• Self-directed with a proactive approach to process improvement
• Familiarity with Lean Manufacturing principles
• Proficiency with MS Office and manufacturing systems (e.g., MES)