Process Engineer

General Responsibility

The Process Engineer is responsible for coordinating the molding efforts on new program launches, setting up and/or revising manufacturing processes and assisting the manufacturing operations in problem solving and continuous process improvements.This position is responsible for leading the efforts to reduce costs, improve efficiencies, reduce quality issues and standardize processes. The position will lead and support material and color samples, new product mold trials, machine/mold design reviews and run-offs, and hands-on productivity initiatives. This position will be responsible for optimizing injection molding and robot processes, developing standard operating procedures and process specification as well ss supporting quality and safety initiatives.

Key roles and Responsibilities

Participate in new tooling design reviews and provide recommendations
Participate in machine and robot design reviews and provide direction to the vendors
Involved in the selection of all new molding machines, robots, tooling and auxiliary equipment
Trial and evaluate new materials, colorants and additives and provide process recommendations
Trial all new, replacement and refurbished tooling and develop recommended process specification
Travel to mold and machine builders to participate in initial trials and run-offs
Setup and programming of robots; troubleshooting EOAT/press interface issues
Develop, manage, and update the molding machineprocess specification library while monitoring historical cycle time based on process and machine capabilities and update accordingly
Manage the mold and machine specifications and compatibility database
Recommend correct set-up of molds, machines&auxiliary equipment before release to production
Responsible for periodic monitoring of product quality and adherence to product specifications
Interact with R&D Product & Design Engineers, Material Engineers, Tooling Engineer on all new products, colorant and material development projects
Works closely with R & D and quality departments on any new project qualifications and PPAP
Provide support to the Technical Supervisors & Process Technicians as required
Develop and implement plans to reduce scrap and improve cycle efficiency
Perform DOE in order tounderstand and optimize processes and define limitations and tolerances
Work on compiling documentation for capital projects, cost savings, ROI, justifications
Provide support and development of VAVE (value added value engineer) cost reduction initiatives
On a day to day basis work with the Planning, Quality, Technical, Maintenance, Mold & Machine shop, and Production departments to coordinate and execute all activities
Performs root cause analysis on any process changes implemented.
Monitors regrind consumption, virgin materials, and overall blends to ensure consistency and reports on how it impacts the process capabilities.
Provide process, operating instructions and training documentation and assist with the training of the technicians

knowledge Skills and Abilities

Hands on Injection Molding processing expertise in a production
Experience working with Husky, Milacron, Engel, and Krauss Maffei injection molding machines
Experience working with high speed side &top entry robots and articulated robotics such as Fanuc, Wittmann, CBW/Mueller is desirable
Knowledge & experience working with and designing End of Arm Tools (EOAT)
Experience working with ancillary equipment including but not limited to hot runner controllers, temperature controllers, materialblenders, resin handling equipment, granulators, and conveyors
Processing knowledge / experience with resin/materials: PP, HDPE, LLDPE, TPE, COPET, SAN, ABS
Knowledge and experience working with colorant, additives and processing aids
Intimate tooling knowledge including core, cavity, ejection,plates, slides, cooling, heating
Intimate knowledge of mold hot runner designincluding but not limited to manifolds, heaters, TC, hot tips, pneumatic & hydraulic valve gates
Experience working with high cavitation molds
Experience working with multi-level stack molds desirable
Thin wall / packaging plastic processing experience desirable
Experience working with automation and packaging equipment
Ability to performtonnage calculations, review mold and machine specifications and determine compatibility, injection unit capacity, cooling / flow requirements
General Knowledge of injection molded part design requirements, constraints and limitations
General Knowledge of injection molded part and processing defects and typical corrective actions
Project management skills including developing action item trackers, timelines &project scope
Understanding of Statistical Process Control (SPC)
Understanding of Scientific molding principles and tools
Experience with PLC & PC, Industrial controls, AC drives, servo motors& drives desirable
Blue Print reading including GD &T
Ability to read and understand Equipment Operations & maintenance manuals
Lean/Six Sigma Problem solving and process improvement tools and methodologies such as 5 Whys, DMAIC, root cause analysis desirable
Experience working with Quality Management Systems, specifications, testing, qualification

Professional Qualifications

BS or MS Engineering Degree(plastics technology preferred)
Or equivalent engineering experience in a manufacturing environment
Minimum of 5+ years of hands on Injection Molding processing expertise
Minimum of 3 – 5 years of experience in manufacturing environment.
Proficient in AutoCAD and Solidworks or comparable CAD/3D modeling
Experience, understanding and interpreting Mold Flow and FEA analysis
Proficient in utilizing business systems such as ERP (SAP), MES (Mattec), CMMS (Micromain)
Competency using Microsoft Office (Word, Excel, Powerpoint, Access, Outlook, etc)
Ability to author technical reports as well as prepare and deliver effective presentations
Ability to complete cost analysis, capital appropriation requests and ROI development
Trained in problem solving techniques, Statistical Process Control, Quality and Lean Manufacturing

Prerred Characteristics

Highly motivated self-starter, flexible, open-minded with a strong work ethic and positive attitude
Proven track record of driving results to meet the organization’s metrics and KPIs
Proven experience in root cause identification and countermeasure implementation and perform validations on new, transferred, or modified processes.
Demonstrated ability to lead and/or participate on cross-functional teams to achieve established goals and objectives.
Strong project management skills. The experience and ability to prioritize and manage multiple development projects simultaneously ensuring all milestones, deadlines, and deliverables are met.
Blend of technical, interpersonal skills, with continuous learning through trainingand mentoring
Must possess strong leadership skills.
Strong interpersonal and communication skills – able to communicate effectively to all levels
Keen understanding of manufacturing processes and the use of machinery to produce a quality product in a manufacturing environment
Must be able to build a strong working relationship with all levels and departments
Work with limited supervision and maintain an atmosphere of cooperation among all departments.