Manufacturing Engineer; Molding

Manufacturing Engineer—Molding Room

The Manufacturing Engineer—Molding Room is responsible for engineering leadership over the FRP tank molding processes, including filament winding, spincast, and the molding of top and bottom heads. This role develops, standardizes, and continuously improves processes, tooling, and materials, and to achieve Safety First, Quality Without Compromise, Customer Focus, Integrity and Accountability, and Teamwork and Respect. The engineer partners closely with Production, Quality, Maintenance, and EHS to ensure reliable throughput, consistent product quality, and regulatory compliance.

Key Responsibilities

Process Engineering & Controls

Own and optimize the filament winding process (e.g., winding patterns, fiber tension, resin impregnation rates, cure profiles, layup schedules, mandrel/liner prep).

Own and optimize the spincast process (e.g., rotational speed/acceleration profiles, resin/filler ratios, viscosity control, gel and cure times, mold temperature, venting).

Own and optimize head molding (top & bottom) including robotics and robot programs, tooling design, reinforcing schedules, gelcoat application, and bond/joint design with cylindrical shells.

Define, document, and audit standard work, SOPs, and work instructions; ensure process consistency across shifts.

Establish and maintain process parameter windows; implement statistical process control (SPC) for critical variables.

Lead trial plans for new resins, glass rovings/mats, additives, gelcoats, release agents, and liners; qualify materials and update specs.

Develop and maintain PFMEA, control plans, and process flow maps; reduce high-risk failure modes.

Quality & Compliance

Partner with Quality to define incoming, in-process, and final inspection criteria (e.g., Barcol hardness, thickness/ply conformity, laminate quality, cure validation, dimensional checks).

Implement root-cause analysis (5-Why, Fishbone, DMAIC) and corrective actions for defects (porosity, dry fiber, resin-rich areas, delamination, voids, dimensional out-of-tolerance).

Ensure compliance with applicable ASME/ASTM test methods, customer specifications, and internal standards (e.g., hydrostatic, vacuum/pressure tests where applicable).

Maintain robust documentation traceability: batch records, cure logs, parameter charts, material certifications.

Safety, EHS & Reliability

Model and enforce OSHA requirements including Lockout/Tagout (LOTO), PPE, machine guarding, housekeeping, chemical handling (resins, catalysts), and ventilation practices.

Collaborate with Maintenance on preventive maintenance and reliability plans for winders, spincast equipment, ovens, molds, and fixtures.

Lead process hazard assessments and implement engineered safeguards; drive near-miss analysis and mitigation.

Throughput & Cost Improvement

Drive continuous improvement in cycle time, first-pass yield, scrap reduction, and OEE for winding/spincast/head lines.

Apply Lean tools (standard work, 5S, visual controls, SMED) to reduce changeover time and improve flow.

Partner with Scheduling to balance labor, equipment capacity, and line takt time; propose staffing models and training plans.

Identify and deliver cost savings (material utilization, waste reduction, energy optimization, tooling life).

Tooling, Equipment & Technology

Design or specify tooling, mandrels, molds, fixtures, and handling aids; manage new equipment commissioning and validation.

Maintain equipment parameter databases, recipe management, and revision control; own engineering change control for process updates.

Evaluate and introduce technologies such as automated fiber tension control, resin metering/monitoring, data logging, and cure monitoring.

Training & Cross-Functional Collaboration

Train operators and leads on process fundamentals, critical-to-quality characteristics, and safe work practices.

Provide technical support to Customer Service and Applications Engineering for manufacturability questions and special builds.

Collaborate with R&D for new product introductions (NPI), pilot runs, and scale-up to steady-state production.

Qualifications

Must be familiar with a variety of the field's concepts, practices, and procedures.

Exp…