Sr. Process Engineer

About the role

The Process Engineer is responsible for the development, optimization and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The Process Engineer plays a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues and ensuring stable manufacturing performance across all molding work centers.

Responsibilities

• Process Development & Optimization:
• Develop, validate and optimize molding processes for:
• LSR injection molding.
• HCR injection, compression and transfer molding.
• Multi-cavity, family molds and multi-shot configurations.
• Apply scientific molding techniques to establish:
• Injection/fill profiles.
• Pack/hold strategies.
• Cure and thermal control profiles.
• Venting and flash prevention parameters.
• Perform process determination and DOE studies to optimize process by improving capability (Cp/Cpk) and reducing variation.
• Establish and maintain standardized process parameter sheets, recipes and work instructions.
• Troubleshooting & Technical Support:
• Provide daily technical support to address molding issues such as:
• Flash, short shots, cure variations, knit lines and voids.
• Sticking and ejection problems.
• Inconsistent shrink, durometer and dimensional stability.
• Lead structured root cause analysis (5 why, 8D, fishbone) and implement robust corrective and preventative actions.
• Train operators and technicians in molding best practices and process discipline.
• Partner with Tooling Engineer on:
• Gate/vent design for silicone and rubber molds.
• Cold runner or valve-gate LSR systems.
• Mold thermal management and vent maintenance.
• Mold qualification and production readiness.
• Support maintenance to ensure equipment (presses, injection units, dosing systems, thermolators) operate within validated performance parameters.
• Provide feedback to improve mold robustness, reduce tool wear and minimize flash related issues.
• Drive improvements in:
• Cycle time optimization.
• Scrap and rework reduction.
• OEE (availability, performance and quality).
• Material usage and yield optimization.
• Participate in LEAN, Kaizen, 5S and efficiency projects.
• Use SPC, data analytics and process monitoring to identify and address instability.
• Cross-Functional Collaboration:
• Work with NPI Engineering on:
• Feasibility reviews.
• New mold trials and qualification.
• Leverage launch readiness and transfer to production.
• Support Quoting/Estimating with:
• Cycle time projections.
• Material behavior expectations.
• Cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks and improvement projects.
• General Accountability:
• Cooperation and professional conduct with coworkers, staff, and managers.
• Communicate effectively with Flexan’s employees and Management. Demonstrates all the Flexan corporate values.
• Quality
• Accountability
• Respect
• Innovation
• Integrity
• Open & honest communications
• Teamwork
• Customer focus

Requirements

• Bachelor’s degree in an Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer)/
• 5+ years’ direct experience in silicone and/or rubber molding, with strong understanding of:
• Liquid Silicone Rubber (LSR) injection.
• High Consistency Rubber (HCR) molding.
• Compression and transfer molding.
• Cure cycles, post-cure and material behavior.
• Tool design elements (cavitation, gating, venting, steel types).
• Strong ability to interpret engineering drawings, GD & T, CAD models, customer and regulatory specifications.
• Demonstrated success in troubleshooting complex molding issues.

Pay

The pay range for this role is $100-$125k. The pay range considers a wide range of factors that include a candidate’s skills; experience and training; licensure and certifications; and geographic location.