Process Engineer

The Process Engineer is responsible for the exploration and potential development of new and existing materials, equipment and processes related to Injection Molding. Collaborate with Engineering, internal & external Product Designers and tool shops to develop parts and molds that are mass production efficient and result in high quality injection molded parts. Establishing or upgrading procedures, troubleshooting and resolving barriers to production schedules.

Focuses on the relevant standards for continuous Quality improvement through a formal commitment to excellence, cost efficiency and reliability.

• Co-ordinate the efforts of the Process Department to provide maximum supports to other departments
• Review current parts that are below quoted rate and make improvements
• Participate in new program launch with engineering, quality, and production department
• Coordinate internal process team meetings and lead process improvements initiatives to resolve ongoing quality issues
• Provide trainings (Automation, Process optimization, Robot, etc) to process set-up technicians
• Evaluate set-up technicians, material handlers, and maintenance technicians on their job performance
• Coordinate and perform mold trials with engineering, quality, scheduling, and production
• Implement and track all procedures involved with Process Control as per quality manual
• Optimize all process parameters with current and new jobs
• Dial in machine pyrometers to make quality parts
• Monitor process books:
  Master & process set-up sheets, Machine & tool preventative maintenance
• Track mold changes, streamline changes for less downtime
• Follow-up on mold repairs
• Participate in selecting new equipment to improve plant efficiency
• Works safely, takes timely action and/or reports unsafe acts or conditions, maintains 5S in work area
• Uses IATF 16949 methodologies to ensure complete customer satisfaction within the authorized budget
• Determine root cause of failures and recommend design, tolerance, process changes and follow-up
• Investigate and address capabilities, non-standard processes and equipment conditions to prevent failures
• Supports work groups in identifying and analyzing problems, weighing relevance and accuracy of information generating and evaluating alternative solutions, resolve process issues and expand
• Regularly review developed processes to ensure they meet or exceed Quality and changing volume requirements
• Utilize AM Methodology and 7 Steps of Die Maintenance for injection molds, fixtures and associated equipment
• Maintain accurate and up-to-date inventory of individual tools and Quality approval status
• Coordinate the manufacture of samples for testing as requested through Product Engineering
• Plan and direct the installation, testing, operation, maintenance and repair of injection molding equipment
• Actively participate on the Product Development Team, providing technical input for team deliverables
• Write and review detailed reports on development work and trials including developing parameters and procedures
• Develop Automation programs for equipment with robotics integrated with other processes
• Obtain quotes, enter purchase requisitions for materials, equipment or services
• Prepare for launch and projects based on technology and resource requirements and specifications
• Supports Manufacturing with technical expertise, IATF 16949:2016 and Stage-Gate activities

• Electronics Engineering Technician, Chemical or Mechanical Engineering Degree preferred
• Minimum of five (5) years plastic manufacturing experience
• Minimum of three (3) years Injection Molding Process experience
• Strong plastics background including educational trainings an asset
• Good problem-solving skills (8D, ATS, DOE, 3-Panel Charts, Time Study)
• Experience in use and interpretation of SPC tools and techniques including X bar and R charts, Pareto analysis, process flow charts, control charts and capability concepts

• Critical thinking and problem-solving tools & techniques
• Ability to pivot, open to applying new, detailed information
• Technical Credibility with hydraulics, pneumatics, tools, dies, jigs, gauges, hydraulics
• Control of Non-conforming Product/Tagging