Process Development Engineer

Role details

Company Overview Stone Plastics is a dynamic manufacturer specializing in advanced plastic molding solutions for a variety of industries, including automotive, furniture, recreation, construction, and appliances. Since our founding, we have grown rapidly by leveraging innovative automation and a relentless commitment to quality. Job Overview The Process Development Engineer exists to ensure every new mold is proven capable, stable, and repeatable before it is released to Production. As the technical owner of sampling and the molding process during launch, this role turns a new tool into a validated, documented process that Production can run right the first time.

The Process Development Engineer partners with the Launch Engineer, who owns the overall launch and APQP template, and hands a fully proven process to the production Process Engineers. Primary Functions

• Own sampling and process development for new molds, from DOE planning and first shots through the validation run.
• Develop, optimize, and document robust molding and packaging processes, including the saved stable process, machine set-ups, and mold documentation.
• Resolve mold, process, and dimensional issues at the press with the Launch Engineer, Tooling, Metrology, and Quality, and verify every tool correction through follow-up sampling.

What Success Looks Like The Process Development Engineer engages during launch planning, before the tool arrives. They support the Launch Engineer on feasibility and mold flow review, prepare the DOE plan, and make sure the press, material, and auxiliaries are ready. When the tool arrives they prep the mold (water lines, sprue, and nozzle tip) and run the RMT, then execute the DOE runs and analysis to establish the process window. The Process Development Engineer owns the molding process during launch: process parameters, cavity-to-cavity and run-to-run consistency, and the machine and peripheral equipment, including dryers, TCUs, hot runner controls, and robotics.

They run the confirmation run (50 parts per cavity, 5 for layout), request the temporary master approval, and support capability, run-at-rate, and PPAP. They lead the packaging test, set up the workstation with Production, and confirm the final pack quantity in X2. They work with the Manufacturing Engineer, who owns EOAT, bulk density, and time studies, so the cell is set up as one complete package. When dimensional or cosmetic issues come up, the Process Development Engineer works at the press with the Launch Engineer, Tooling, Metrology, and Quality to find root cause and tell process issues apart from tool issues.

After each tool adjustment they run the follow-up sample (including the 165-piece split) to verify the correction, and they report results to the Launch Engineer so the APQP Open Issues List and template stay current. At the capable-part and validation run they save the stable process, complete the machine, robot, and HAL set-ups, build the mold doc book, and support the PFMEA and control plan. At close they confirm cycle time against the quote and hand off to the production Process Engineers. Success means validated process sheets and set-up documentation that Production can run consistently: each mold is not simply sampled, but fully proven. Desired Qualifications

• Process Engineering degree preferred
• Associate's degree with 5 years of experience, or 10+ years of injection molding experience
• RJG Master Molder certification or equivalent scientific molding training
• Hands-on experience setting up molding machines, hot runners, and auxiliary equipment (dryers, TCUs, and robotics)
• Experience with DOE, Cpk/Ppk, and SPC; Minitab or similar statistical software a plus
• Ability to read prints and GD&T and interpret dimensional reports
• Experience supporting APQP, PFMEA, control plans, and PPAP
• Ability to communicate effectively with the Launch Engineer, Tooling, Metrology, Quality, and Production
• Systematic troubleshooting and problem-solving skills
• Self-starter able to work on tight launch timelines
• Understanding of Lean concepts (standardized work, problem solving, and set-up and scrap reduction)
• Ability to mentor and develop others
• This role requires regular and consistent attendance.