The Senior Process Engineer will lead the development, optimization, validation, and troubleshooting of injection molding processes to improve quality, efficiency, and overall manufacturing performance. This is a highly visible technical leadership role focused on scientific molding, continuous improvement, and supporting new product launches from sampling through production.
Client Details
Our client is an employee-owned manufacturing organization known for solving complex engineering and production challenges for leading global brands. The company offers a collaborative, innovation-driven environment where employees have direct influence on business success and long-term growth.
Description
- Develop, optimize, and maintain injection molding processes for both new and existing programs utilizing scientific molding methodologies.
- Lead mold sampling, process development, production launches, and validation projects.
- Establish robust process controls and collaborate with Quality teams to ensure consistent product performance.
- Troubleshoot molding, tooling, automation, material, and equipment-related issues to minimize downtime and improve efficiency.
- Analyze process data and implement improvements related to quality, cycle time, throughput, and process capability.
- Create and maintain process documentation including setup sheets, work instructions, validation protocols, and operating standards.
- Support the development and maintenance of PFMEAs, Control Plans, process flows, and manufacturing documentation.
- Participate in mold design reviews, print reviews, and material selection evaluations.
- Provide technical input on tooling, automation, and equipment designs to support manufacturing objectives.
- Design and execute DOE studies, process validations, and capability assessments.
- Drive continuous improvement initiatives focused on scrap reduction, cycle time optimization, cost savings, and operational excellence.
- Partner with Operations, Tooling, Maintenance, Engineering, and Quality teams to strengthen troubleshooting and process improvement efforts.
- Serve as a technical resource for complex molding defects, dimensional challenges, and production issues.
- Mentor and train Process Technicians, Setup Technicians, and Operations personnel on scientific molding principles and best practices.
- Leverage Lean Manufacturing, Six Sigma, SPC, and statistical analysis tools to support performance improvements.
- Monitor and report key manufacturing metrics including OEE, downtime, yield, scrap, and efficiency.
Profile
- Bachelor's degree in Manufacturing, Mechanical, Plastics, Industrial Engineering, or related field.
- 8+ years of hands-on process engineering experience within plastics manufacturing, with strong injection molding expertise.
- Proven experience developing, optimizing, documenting, and troubleshooting injection molding processes in a manufacturing environment.
- Strong background in scientific molding, decoupled molding, process window development, tooling, resin behavior, drying requirements, and secondary operations.
- Experience with mold sampling, process validation, capability studies, CAPA investigations, root cause analysis, and MRB activities.
- Knowledge of Lean Manufacturing, Six Sigma, DOE, SPC, GD&T, PFMEA, and Control Plans.
- Experience with CAD software and manufacturing systems; experience with Moldflow, RJG/eDART, cavity pressure monitoring, or similar technology is preferred.
- Strong project management, leadership, mentoring, communication, and problem-solving skills.
- Ability to interpret engineering documentation, technical drawings, and manufacturing process specifications.
Job Offer
- Competitive salary ranging from $110,000 to $135,000 per year.
- Experience within ISO 13485 or other regulated manufacturing environments.
- Certifications or formal training related to Lean Manufacturing, Six Sigma, Scientific Molding, or Plastics Engineering.
- Experience supporting medical device, precision manufacturing, or highly regulated production environments.
MPI does not discriminate on the basis of race, color, religion, sex, sexual orientation, gender identity or expression, national origin, age, disability, veteran status, marital status, or based on an individual's status in any group or class protected by applicable federal, state or local law. MPI encourages applications from minorities, women, the disabled, protected veterans and all other qualified applicants.