Sr Engineer, Plastics

The Plastics/Injection Molding Engineer is responsible for driving mold process development and injection molding projects through adherence to established product design, scientific injection molding process, tooling, resin, and equipment. The key responsibility of this position is to lead molding qualification activities and continuous improvement with established manufacturing. Responsible for leading projects and actions that result in improved quality, process stability, and reduced cost.

Duties and Responsibilities

• Experienced in setting up robust injection molding processes on multi-cavity molds and insert molding
• Experienced in process development utilizing Scientific Molding and Design Of Experiments (DOE) principles
• Subject matter expert in the ability to coordinate qualification activities (PPAP, IQ, OQ, PQ, DOE, etc.) to meet requirements of the application.
• Highly proficient in generating qualification requirements and reports for injection molded components
• Use and understanding of in-cavity sensors for process development
• Plan and execute new tool samples and/or attend tool samples performed at outside sources
• Prepare or update procedures, work instructions and process sheets as required
• Subject matter expert during product design reviews for manufacturing feasibility
• Understanding of Mold Flow analysis
• Knowledge of both Crystalline & Amorphous plastics resin (examples include polycarbonate, acrylic, PVC, Nylon and Co-polyesters)
• Use of Society of Plastics Industry Standards (SPI) for mold build classification and texture/surface appearance recognition
• Use and understanding of Statistical Tools (Design of Experiments, Measurement System Analysis/Gage R&R, Process Capability and Statistical Process Control)
• Develop and maintain strong working relationship with functional groups (Engineering, Quality Operations, Manufacturing)
• Proactively perform process improvement activities on existing processes to improve efficiencies, increase production output, reduce scrap, waste, handling damage, and non-conformances.
• Continuous improvement activities focused on cost reduction and communication of cost reduction project status.
• Responsibilities for some or all of the following: project management, process development, process print development, development of work instructions, and operator training on manufacturing processes.
• Become Subject Matter Expert for assigned processes and support customer, ISO, FDA, and internal audits.
• Comply with department procedures and ISO and FDA regulations.
• Development and implementation of process improvement projects as well as new process development, including working with outside contractors.
• Discovers potential problems, solves problems, and implements changes in primary and secondary operation processes.
• Responsible for working as part of the cell team to improve customer service, reduce scrap, reduce lead-time, improve product flow, reduce product cost, and provide smooth implementation of new products.
• Work with other engineers and production operators in process development.
• Occasionally responsible for working with Quality Engineering to develop quality plans and ensure compliance with Good Manufacturing Practices.
• Once employee demonstrates competency in position, he/she may be required to train others in similar roles.
• Strong history of mentoring coworkers in overall personal development

Education and Experience

• Preferred 4 Year/ Bachelors Degree in Plastics Engineering, Process Engineering, or related field. 8-10 years experience in Plastics environment.
• Thorough working knowledge of primary or secondary production equipment and processes required.
• Experience utilizing statistical techniques such as process capability and Gage R&R is strongly preferred.
• Experience performing productivity tests and evaluations such as OEE, TPM, etc. is strongly preferred.
• Should have demonstrated ability in leading projects through the evaluation of information and responding accordingly using project management tools such as Gant charts, etc.
• Experience in new mold process development for new product rollouts is preferred.

KSA's

• Excellent oral and written communication skills required.
• The ability to work as part of a cellular team is essential to the job.
• Ability to work and contribute in a team oriented, continuous improvement, manufacturing environment.
• Personal computer, problem solving, team building, and SPC skills required.
• Excellent organizational skills and attention to detail required.
• Excellent follow-up skills required.
• Ability to independently solve problems and make recommendations.

Physical Demands

• Frequent sitting, frequent standing, frequent walking.
• Use hand/fingers to grasp/pinch/grip Occasional climbing (stairs/ladders) or balancing.
• Occasional stoop, kneel, crouch, or crawl.
• Occasional operating of machinery and/or hand power tools.