Injection Molding Process Engineer

Position Summary

The Injection Molding Process Engineer is responsible for developing, optimizing, and maintaining injection molding processes to ensure efficient production, consistent quality, and adherence to safety standards. This role works closely with production, quality, and maintenance teams to introduce new products, improve existing processes, and support continuous improvement initiatives.

Essential Duties and Responsibilities

Process Development & Optimization

• Develop, document, and implement molding processes for new and existing products.
• Establish and maintain standard process parameters to ensure consistent product quality and cycle times.
• Lead trials for new molds, materials, and equipment, ensuring readiness for full-scale production.

Troubleshooting & Problem Resolution

• Analyze and resolve molding issues such as dimensional inconsistencies, surface defects, material flow problems, and process inefficiencies.
• Support production teams with technical guidance and root cause analysis for process-related downtime.
• Collaborate with tooling, material suppliers, and equipment vendors to address technical concerns.

Quality & Compliance

• Partner with Quality Assurance to ensure processes meet customer specifications and applicable quality standards.
• Implement process controls, validation protocols, and inspection plans to maintain product quality.
• Ensure compliance with all applicable safety, environmental, and regulatory requirements.

Continuous Improvement

• Lead Lean Manufacturing, Six Sigma, and continuous improvement initiatives to reduce waste, improve productivity, and enhance product quality.
• Identify and recommend equipment upgrades, automation opportunities, and emerging technologies.
• Train, coach, and mentor process technicians, setup personnel, and operators on best practices and standardized work procedures.

Documentation & Reporting

• Maintain accurate process sheets, setup documentation, validation records, and troubleshooting guides.
• Prepare reports related to process capability, scrap reduction, downtime reduction, and efficiency improvements.
• Analyze production data and metrics to identify trends and recommend corrective actions.

Qualifications

Education and Experience

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Plastics Engineering, or a related field; equivalent combinations of education and experience may be considered.
• Minimum of three (3) years of experience in injection molding process engineering within a manufacturing environment preferred.
• Experience with thermoplastic materials, injection molding equipment, process validation, and scientific molding techniques.

Knowledge, Skills, and Abilities

• Strong knowledge of scientific molding principles, Design of Experiments (DOE), process validation, and root cause analysis.
• Ability to read and interpret engineering drawings, CAD models, technical specifications, and quality requirements.
• Proficiency with statistical analysis tools, manufacturing software systems, and Microsoft Office applications.
• Strong analytical, organizational, problem-solving, and project management skills.
• Effective verbal and written communication skills with the ability to collaborate across departments.

Work Environment

• Work is performed in both office and manufacturing environments.
• The manufacturing environment may include exposure to moving machinery, elevated noise levels, temperature variations, industrial chemicals, and airborne particulates.
• Appropriate personal protective equipment (PPE) must be worn as required.

Physical Requirements

• Ability to move throughout office and manufacturing areas to observe processes, evaluate equipment, and support production operations.
• Ability to inspect equipment, molds, and manufactured products, including positioning oneself to access equipment and work areas.
• Ability to communicate effectively with employees, vendors, and customers in person, by phone, and electronically.
• Ability to operate standard office equipment and utilize computer systems for extended periods.
• Ability to occasionally lift, carry, push, or pull materials, tools, or equipment weighing up to 25 pounds.
• Ability to travel within the facility and occasionally between locations as business needs require.

Work Schedule

This is a full-time position. Occasional overtime, weekend work, or schedule adjustments may be required to support production demands, process trials, equipment installations, and project deadlines.

Equal Employment Opportunity and Reasonable Accommodation

Spaulding Composites is an Equal Opportunity Employer and provides equal employment opportunities to all employees and applicants in accordance with applicable federal, state, and local laws. Qualified individuals with disabilities may be entitled to reasonable accommodations to perform the essential functions of the position. Requests for accommodation will be considered in accordance with applicable law.