Sr Engineer, Plastics

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

KSA's

• Excellent oral and written communication skills required.
• The ability to work as part of a cellular team is essential to the job.
• Able 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.