Molding Process Engineer

Role details

Position Objective

The Senior Molding Process Engineer provides advanced technical leadership and ownership of injection molding process development, validation, standardization, and continuous improvement. This position serves as the primary technical resource for complex molding challenges and leads initiatives to improve safety, quality, productivity, and manufacturing cost. The role collaborates with Tooling, Engineering, Quality, Maintenance, and Production while mentoring technical personnel and establishing consistent molding practices across shifts.

Key Responsibilities

• Lead the development, validation, and optimization of injection molding processes for new and existing products.
• Establish molding process standards, validated operating windows, and process control strategies for consistent quality and performance.
• Serve as the technical escalation point for complex molding defects, recurring process issues, and production instability.
• Lead mold trials, process qualifications, and production validations; coordinate first article inspections with Quality.
• Lead process engineering for new mold launches, engineering changes, and startups, including readiness reviews and handoff to Production.
• Apply scientific molding, Design of Experiments (DOE), and statistical analysis to develop robust, repeatable processes.
• Partner with the Tooling Engineer to improve mold performance, cooling, venting, gating, and reliability.
• Lead improvement projects targeting scrap, cycle time, throughput, downtime, and Overall Equipment Effectiveness (OEE).
• Analyze process data, prioritize improvement opportunities, and verify sustained results.
• Lead cross-functional root cause investigations and ensure corrective and preventive actions address underlying causes.
• Establish and maintain process documentation, standard operating procedures, setup sheets, and specifications.
• Evaluate molding equipment, automation, robotics, and auxiliary systems; support capital proposals, specifications, installation, and qualification.
• Provide technical leadership and mentoring to Process Engineers, Process Technicians, Team Leaders, and production personnel.
• Develop technical training and consistent setup, troubleshooting, and process control practices across shifts.
• Partner with Quality to investigate customer concerns and verify corrective action effectiveness.
• Ensure process changes follow change-control procedures, safety policies, quality standards, applicable ISO requirements, and customer specifications.

Authorities

• Approve molding parameters, operating windows, and process validation documentation within assigned authority.
• Establish technical standards for molding setup, monitoring, troubleshooting, and optimization.
• Stop production when process conditions compromise product quality or safety.
• Lead technical investigations and direct process-related corrective actions.
• Review and recommend tooling modifications, equipment upgrades, automation, and capital improvements.
• Recommend technical priorities and project resources to the Molding Manager.
• Provide technical direction for molding improvement projects and production launches.

Required Skills and Competencies

• Advanced knowledge of injection molding, thermoplastic materials, and high-volume plastics manufacturing.
• Expert understanding and practical application of scientific molding principles.
• Strong knowledge of mold design, tooling, resin processing, cooling systems, venting, and gating.
• Advanced troubleshooting and root cause analysis skills for complex molding problems.
• Proficiency in process validation, DOE, statistical process control (SPC), and process capability analysis.
• Knowledge of automation systems, robotics, and auxiliary molding equipment.
• Ability to translate process data into prioritized improvements and measurable manufacturing results.
• Strong project management skills, including planning, coordination, risk assessment, and follow-through.
• Ability to lead cross-functional teams and mentor technical personnel.
• Proficiency with Microsoft Office, ERP systems, and engineering documentation software.
• Excellent communication skills and sound technical judgment.
• High degree of integrity, professionalism, confidentiality, and accountability.

Education Requirements

• Bachelor’s degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related engineering discipline required.
• RJG Scientific Molding certification preferred.
• Advanced scientific molding or Master Molder training preferred.
• Lean Six Sigma Green Belt or higher preferred.

Experience Requirements

• Minimum of seven (7) years of progressive injection molding process engineering experience, including demonstrated technical leadership.
• Demonstrated success independently resolving complex molding issues and sustaining quality, productivity, and cost improvements.
• Significant experience with scientific molding, process validation, and mold qualification.
• Experience leading new mold launches and product introductions from trials through stable production.
• Experience leading cross-functional improvement projects and managing multiple technical priorities.
• Experience mentoring engineers, technicians, and production personnel.
• Experience evaluating molding equipment, automation, or capital improvement projects preferred.

Training Requirements

• Successful completion of company onboarding requirements.
• Annual ethics and compliance training.
• Maintain applicable engineering, safety, and quality certifications.
• Complete advanced technical and leadership training as required for the position.
• Complete additional training as assigned based on equipment, process changes, customer requirements, or business needs.

Pay: $80,000.00 - $90,000.00 per year

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Flexible spending account
• Health insurance
• Life insurance
• Vision insurance

Work Location: In person