Advanced Molding Group Process Engineer

Job Summary

The Advanced Molding Group Process Engineer is responsible for optimizing new injection molded parts and processes for production, focusing on higher-risk projects.

Responsibilities

• Work with others to get assigned projects into production with acceptable OEE and risk level.
• Provide guidance and mentoring to process engineers and technicians, as well as the project teams, to continuously improve all aspects affecting process engineering.
• Recommend learning opportunities for others.
• Collaborate with materials engineers, mold tooling engineers, and quality engineers to ensure systems and processes are optimized.
• Promote change where needed.
• Evaluate and recommend screw geometry, non-return valves, auxiliary equipment like dryers and blenders, etc.
• Use and explain different root cause failure analysis techniques.
• Work with the materials engineer to recommend appropriate analytical methods and coordinate needed actions internally or with outside labs.
• Recommend hot runner setups.
• Collaborate with maintenance to establish proper preventive maintenance cycles on the presses and equipment.
• Aid the Director of Manufacturing and the Training Department in evaluating training needs for Process Engineers and Process Technicians.
• Explain APQP, write and evaluate PFMEAs, and how all of it gets incorporated through Control Plans and level 3 PPAPs.
• Set up, run, and evaluate DOE's and make appropriate recommendations when needed.
• Aid the Director of Manufacturing in evaluating and making recommendations on key process-related equipment.
• Assist with other duties as assigned.

Essential Functions

• Injection molding: Set a mold and establish robust processes on a variety of injection molding machines across a variety of resins using scientific injection molding.
• Injection molding auxiliary equipment: Use/evaluate/recommend moisture analyzers, blenders, dryers, mold temperature control units, hot runner controllers, etc.
• Heat transfer: Explain, calculate, and recommend mold cooling requirements. Explain and figure out shear-induced flow groups and recommend appropriate course of action when fill-imbalance mitigation is needed, and how best to do that.
• Application of statistics: Interpret various statistical tools such as Cp, Cpk, and standard deviation. Calculate gate sizes using shear rate.
• Explain mechanical mold design from a structural perspective. Explain flow analyses. Explain APQP, write and evaluate PFMEAs, and how all of it gets incorporated through Control Plans and level 3 PPAPs.
• Part inspection: Read part drawings, preferably including GD&T, and perform basic measurements.
• Clear and concise written and verbal communication skills. Have and maintain a teachable point of view and an ability and aptitude to help others learn.
• Understand hygroscopic resin moisture absorption, desorption, and resin moisture effects on processing and part performance. Explain and evaluate scientific injection molding practices.