Injection Molding Process Engineer

Essential Job Functions and Responsibilities

• Develop, design and setup robust molding processes utilizing scientific and decoupled molding, by running SMPD, DOEs, OQs, and PQs run.
• Create documentation of molding set-ups, processes, and workflows.
• Quantify current process capabilities as a foundation for evaluating and improving processes and products.
• Improve production efficiencies by improving cycle times, reducing scrap, improving setup time, workstation layout and yield, by implementing cGMP.
• Troubleshoot defects and trace to the root cause to determine how to change the process or the mold to eliminate the future occurrence.
• Audit processes to verify documented process match actual process being used.
• Ensure Setup and Process Techs are processing jobs correctly.
• Maintain up to date the “Part Number Info” in the database.
• Answers customer complaints and implements corrective action when necessary to resolve issues.
• Provide advanced engineering support in the areas of design, manufacturing process, material characteristics related to the development and manufacture of the product.
• Lead process improvement team using modern manufacturing tools and methods, e.g., Lean, Kaizen, Six Sigma, cGMP, etc.
• Cook with mold validations and tests with scheduling, molding, tool room, and quality department.
• Evaluate each process for automation, cycle efficiencies, and reduction of labor.
• Work with the tool room to improve manufacturing capabilities of new and existing tooling.
• Train and assist with mentoring of Process Technicians, Setups and key operations personnel to develop and enhance process knowledge and skills.
• Work with Engineering, Production, Quality and Maintenance groups to establish, execute and monitor preventive maintenance programs.
• Work with the Program manager as support to meet project deadlines.
• Lead, participate in, or support continuous improvement activities.
• Work with vendors and suppliers, customers and other outside technical resources to develop and improve manufacturing methods that contribute to the reduced product cost and improved product performance.
• Work with Internal and External customers during product development to assure the product meets part print and function.
• Work close with Tool development Engineer, Tool Room Manager, Production Manager, Maintenances Manager and Quality Manager to maintain a teamwork environment
• Ensure safe work environment and participate fully in Safety programs.

Core Competencies

• Awareness, agreement and advancement of company values and goals
• Advanced level knowledge of engineering plastics, resins, and polymers.
• Good verbal, written communication, and presentation skills and the ability to interface within a cross-functional team environment.
• Extensive knowledge of injection molding machines and accessory equipment (robots, grinders, water systems/water treatment) a must.
• Mechanical skills.
• Must have mechanical skills.
• Must be able to read part prints and use measuring equipment (calipers, comparators, etc.).
• Better communication and basic computer skills.
• In-depth knowledge of multi-component molding, design of experiments, basic statistics, insert molding, mold-flow analysis, and various types of process monitoring tools and techniques.
• Experience and knowledge in Statistical Process Control (SPC) principles, Multi-variable Analysis (MVA), and various types of injection molding process data collection/analysis systems.

Education and/or Experience

• Bachelor of Science or equivalent experience required
• experience More than 5 years of engineering experience in a Medical manufacturing environment.
• RGJ Master Molder 1 Certification required.
• RGJ Master Molder 2 (desired not required).
• FimmTech Certification (desired not required).