Process Engineer

Job Responsibilities

• Develop, establish, optimize, and maintain injection molding processes to achieve safety, quality, delivery, and productivity objectives.
• Support new product launches by participating in APQP activities, process development, mold trials, run-at-rate events, PPAP submissions, and customer launch requirements.
• Lead process validation activities including machine parameter development, window studies, capability studies, and production readiness evaluations.
• Troubleshoot molding defects, process variation, tooling concerns, and equipment issues using structured problem-solving methodologies.
• Analyze process performance data and implement corrective actions to improve quality, efficiency, and overall equipment effectiveness (OEE).
• Collaborate with Tooling, Maintenance, Production, and Quality teams to resolve technical issues and support stable production operations.
• Monitor and improve key manufacturing metrics including scrap, cycle times, downtime, labor efficiency, productivity, and process capability.
• Develop and maintain process documentation including setup sheets, process parameters, work instructions, PFMEAs, control plans, and standardized work.
• Identify and implement continuous improvement initiatives focused on waste reduction, cycle time improvement, cost reduction, and operational efficiency.
• Assist in equipment selection, process development, automation implementation, and capacity planning for new and existing programs.
• Conduct root cause investigations and lead corrective action activities related to internal defects, customer complaints, and warranty concerns.
• Train and support Production Supervisors, Process Technicians, and operators on process standards and best practices.
• Participate in layered process audits, quality audits, and customer audits as required.
• Support material evaluations, process trials, and new technology implementation initiatives.
• Analyze production capacity, machine utilization, and cycle times to identify constraints, support customer demand requirements, and develop plans to optimize available capacity.
• Lead capacity planning activities for new program launches and existing production, including equipment requirements, tooling needs, labor utilization, and future growth projections.
• Evaluate production performance against capacity models and implement process improvements to increase throughput, reduce bottlenecks, and improve overall equipment effectiveness (OEE).
• Collaborate with Operations and Program Management to support quote reviews, feasibility assessments, and capacity studies for new business opportunities.
• Ensure compliance with IATF 16949, customer-specific requirements, environmental requirements, and company policies.
• Support additional manufacturing operations and special projects as assigned to meet business needs.

Job Qualifications

• Bachelor's Degree in Engineering (Mechanical, Manufacturing, Plastics, Industrial, or related discipline) preferred.
• Minimum 3-5 years of engineering experience in automotive manufacturing, preferably within injection molding operations.
• Strong knowledge of injection molding processes, scientific molding principles, polymer materials, and mold design fundamentals.
• Experience supporting automotive program launches, APQP, PPAP, PFMEA, Control Plans, and customer-specific requirements.
• Demonstrated ability to troubleshoot molding defects such as short shots, flash, sinks, warpage, splay, burn marks, and dimensional concerns.
• Experience with process optimization, cycle time reduction, scrap reduction, and process capability improvement.
• Knowledge of Lean Manufacturing, Continuous Improvement, and structured problem-solving methodologies.
• Familiarity with robotics, automation systems, hot runner systems, mold temperature control systems, and auxiliary equipment.
• Experience utilizing SPC, process capability studies, MSA, and data analysis tools.
• Strong project management, organization, and communication skills.
• Proficiency with Microsoft Office, ERP systems, and manufacturing data collection systems.
• Able to read and interpret engineering drawings, GD&T, specifications, and technical documentation.
• Strong analytical and root-cause investigation skills.
• Able to manage multiple projects and priorities in a fast-paced automotive manufacturing environment.