Process Engineer

The Injection Molding Process Engineer plans, directs, and coordinates manufacturing equipment and processes to produce high quality injection molded product. The Process Engineer will also be responsible for New Product Introduction (NPI) tool de-bugging, process development, tool validation, and work instructions as well as supporting other engineers on projects as an injection molding and process development subject matter expert. As this is a hands-on position, the candidate will spend approximately 80% of their time in the manufacturing area or in the toolroom supporting NPI and continuous improvement activities. While monitoring the effectiveness of processes this individual quantifies results, documents, and presents findings to management and prepares reports. This position also mentors and provides training to other injection molding personnel. Position must work closely with other departments to provide information in a timely manner.

Responsibilities:

• Utilize decoupled molding techniques and execute design of experiments when necessary to optimize processes and establish process limit conditions.
• Establish process control on all processes running capability studies and determining process alarms.
• Determine and set-up packaging and secondary requirements working with Project Engineer
• Implement Lean methodologies (visual factory, VSM, standard work, SMED, one-piece flow, 5S) to drive continuous improvement on the floor.
• Troubleshoot process as required using formal problem-solving techniques to establish root cause.
• Develop and maintain process documentation ensuring that processes and procedures are clearly stated and understandable for all employees. Provide technical support/solutions to manufacturing processes, improve yield and throughput, drive cost reduction activities and improve on part quality.
• Process Audit documentation to ensure floor compliance.
• Critical NPI team member make recommendations on equipment, material, and tooling to support new business while providing timelines for process implementation.
• Drive new product sampling process to ensure acceptable samples are sent out to customer in a timely basis.
• Drive the Validation and PPAP protocol execution process to ensure customer requirements are met in a timely basis.
• Participate and give recommendations in tool design reviews.
• Create processes through tool design and material process conditions evaluation.
• Demonstrated ability to start-up, operate and shut down process related equipment. Must be able to work independently on new process development as well as troubleshooting current production issues.
• Monitor and report issues with injection molds, make recommendations for refurbishment based on production factors such as cycles, process capability and tooling history.
• Work with equipment and material vendors to resolve machine and material issues.
• Measure and visually inspect products perform Gauge R/R Studies as required.
• Interact with customers to resolve issues and provide new project updates.

Qualifications:

• BS in engineering and 2-5 years of experience with Injection Molding Processes including engineering resins (high temperature a plus)
• Process Control implementation
• Tool design for manufacturability recommendations to ensure process optimization.
• Metrology and Gauge Fixturing
• Proven Six Sigma/Lean Implementation Background
• Familiarity with Secondary Processes (Machining, Gluing, Assembly, Packaging, etc.)
• Automation experience a plus
• Experience with Validation and PPAP requirements.
• Must be capable of supporting validation definition and execution (IQ, OQ, PQ), test method definition, root cause analysis, gage R&R, and measurement systems analysis (MSA) (Required).
• Blueprint and geometric tolerance knowledge (3-D and 2-D Cad experience a plus)
• The ability to perform statistical analysis using DOE, and Process Capability Studies
• Experience and understanding of de-coupled injection molding and structured process optimization/problem solving methodology (Required).
• Proven continuous improvement implementation.
• Ability to work self-directed.
• Exceptional follow-up skill set.
• Proficient with Microsoft Office and Minitab (i.e. graphs, charts, formulas)
• Experience with Moldflow, Cool and Warpage analysis
• Experience with RJG pressure transducer technology
• Experience and confident using SolidWorks.
• Knowledge of CT Scanning a plus
• Experience and understanding of the development and design of plastics injection-mold fabrication processes, insert molded parts, and assemblies (Preferred).
• The ability to conduct design review(s) of hot/cold runner injection molds (Preferred).
• The ability to manage the customer and entire project to completion.

Behaviors:

• Required:
• Innovative: Consistently introduces new ideas and demonstrates original thinking
• Team Player: Works well as a member of a group
• Detail Oriented: Capable of carrying out a given task with all details necessary to get the task done well
• Dedicated: Devoted to a task or purpose with loyalty or integrity
• Motivations:
• Required:
• Growth Opportunities: Inspired to perform well by the chance to take on more responsibility
• Flexibility: Inspired to perform well when granted the ability to set your own schedule and goals
• Self-Starter: Inspired to perform without outside help
• Ability to Make an Impact: Inspired to perform well by the ability to contribute to the success of a project or the organization

Education:

• Required: Bachelors or better

Experience:

• Required:
• 2-5 years: Experience and understanding of de-coupled injection molding and structured process optimization/problem solving methodology.
• 2-5 years: Experience with Injection Molding Processes including engineering resins (high temperature a plus)

Equal Opportunity Employer This employer is required to notify all applicants of their rights pursuant to federal employment laws. For further information, please review the Know Your Rights notice from the Department of Labor.