Sr. Process Engineer

Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations, and ordinances. Job Title: Sr. Process Engineer Location: Lincolnshire, IL About Us 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, gasses, 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 are driving growth with an entrepreneurial spirit and ownership mindset. Learn more at irco.com and join us to own your future. Job Overview 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. ResponsibilitiesProcess Development & Optimization Develop, validate, and optimize molding processes for LSR injection molding. 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, and venting and flash prevention parameters. Performs 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. Troubleshooting & Technical Support 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, 8D, fishbone) and implement robust corrective and preventative actions. Train operators and technicians in molding best practices and process discipline. Tooling & Equipment Interaction Partner with Tooling Engineer on gate/vent design for silicone and rubber molds. Cold runner or valve-gate LSR systems. Mold thermal management and vent maintenance. Mold qualification and production readiness. Support maintenance to ensure equipment (presses, injection units, dosing systems, thermolators) operate within validated performance parameters. Provide feedback to improve mold robustness, reduce tool wear, and minimize flash-related issues. Continuous Improvement Drive improvements in cycle time optimization. Scrap and rework reduction. OEE (availability, performance, and quality). Material usage and yield optimization. Participate in LEAN, Kaizen, 5S, and efficiency projects. Use SPC data analytics and process monitoring to identify and address instability. Cross-Functional Collaboration Work with NPI Engineering on feasibility reviews, new mold trials and qualification, launch readiness, and transfer to production. 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. General Accountability Cooperation and professional conduct with coworkers, staff, and managers. Communicate effectively with Flexans employees and Management. Demonstrates all the Flexan corporate values: Quality, Accountability, Respect, Innovation, Integrity, Open & honest communications, Teamwork, Customer focus. Requirements Bachelors degree in an Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer). 5 years direct experience in silicone and/or rubber molding with strong understanding of: Liquid Silicone Rubber (LSR) injection. High Consistency Rubber (HCR) molding. Compression and transfer molding. Cure cycles, post-cure, and material behavior. Tool design elements (cavitation, gating, venting, steel types). Experience using DOE, SPC, and statistical tools for process improvement. Strong ability to interpret engineering drawings, GD&T, CAD models, customer, and regulatory specifications. Demonstrated success in troubleshooting complex molding issues. Preferences Experience with SolidWorks or other 3D modelling software. Experience with mold flow analysis or ability to interpret results. Background in medical, automotive, aerospace, or industrial silicone components. Experience supporting APQP, PPAP, and customer audits. Experience with automation, vision inspection, and deflashing/trimming technologies. Background with adhesion/bonding techniques, multi-shot molding, and overmolding. RJGPaulson certification or silicone-specific molding training. Familiarity with ISO13485 and clean room procedures would be beneficial. Travel & Work Arrangements Onsite. Compensation The pay range for this role is $100k - $125k. The pay range considers a wide range of factors that include a candidates skills, experience, training, licensure, certifications, and geographic location. What We Offer At Ingersoll Rand, we embrace a culture of personal ownership - taking responsibility for our company, our communities, and our environment as well as our individual health and well-being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental, and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401k plan, paid time off, and even an employee stock grant among other offerings. These benefits are our commitment to you so you can be your best at work and beyond. Ingersoll Rand Inc. (NYSE:IR), driven by an entrepreneurial spirit and ownership mindset, is dedicated to helping make life better for our employees, customers, and communities. Customers lean on us for our technology-driven excellence in mission-critical flow creation and industrial solutions across 40 respected brands where our products and services excel in the most complex and harsh conditions. Our employees develop customers for life through their daily commitment to expertise, productivity, and efficiency. For more information, visit www.IRCO.com. Ingersoll Rand is committed to achieving workforce diversity reflective of our communities. We are an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations, and ordinances.