The Process Engineer leads all efforts in developing, documenting, verifying, and maintaining current and new injection molding processes with a focus on improving quality and cycle performance, works with engineering to reduce part weight, mold configuration times and mold setup times using continuous improvement tools including Lean, PDCA, 5S, Six Sigma, SMED, Value Stream Mapping, Standardized Work, and Theory of Constraints. This position trains and mentors production staff in molding techniques and provides technical leadership and advanced trouble-shooting of challenging mold setups and molding processes.
ESSENTIAL DUTIES AND RESPONSIBILITIES
Identifies and implements process-specific best practices, including new mold and mold repair validation.
Identifies and resolves process and quality related problems using sound problem solving methodologies.
Develops standardized documentation including one point lessons, visual aids, and work instructions.
Provides input into the production schedule and assists staff to ensure that customer orders are completed and delivered within established lead times and at an acceptable quality and cost.
Develops, leads and executes cross functional process improvement projects to meet operational targets.
Provides accurate and timely project reporting to leadership and other internal stakeholders.
Optimizes current processes and identifies emerging technologies for future implementation.
Verifies and approves all process, tooling and equipment validation and qualification settings in accordance with the Release for Sales process on new products.
Investigates product quality problems, determines root cause, gathers and analyzes data and implements corrective actions to reduce or eliminate cause.
Helps facilitate continuous improvement and learning across all functional areas through training and communication of key initiatives
Establishes adequate controls and manages a Continuous Improvement Program to constantly improve molding operations and resolve production problems in order to improve quality, reduce costs, and minimize negative impacts on delivery performance.
Develops and implements an effective preventative maintenance program to lower costs, improve efficiency and maximize asset longevity and OEE uptime.
Maintains a positive work environment that is consistent with the company’s mission and core values.
Ensures timely and effective communication with other departments and the leadership team.
Monitors results; observe and coach department staff on process issues.
Ensures a safe work environment that is fully compliant with company policies and OSHA rules and regulations; as well as all other applicable federal, state and local laws, rules and regulations.
Performs other duties as assigned
Ensures all production is performed efficiently and in accordance with the company’s Quality Management System.
Manages in-process inspection and testing procedures in accordance with established standards and methods.
Ensures prompt disposition of quality hold tags, process RMA/Warranty claims and completes Corrective and Preventative Action items (CAPAs) in a timely manner.
Ensures that assigned area of responsibility remain compliant with all applicable ISO-9001 quality standards.
Monitors the Operations Dashboard and Key Performance Indicators (KPIs) on a daily basis and provides data and feedback to the leadership team as requested.
Assists in developing capital expenditure recommendations.
Ensures that all department assets are properly managed and safeguarded.
Assists in strategic planning and organizational development efforts.
Special projects and initiatives, as assigned.
Quality of WIP Components
Timely Availability of WIP Components to Support On-time Delivery Performance
Mold Configuration, Mold Setup and Process Efficiency
Molding Department Capacity Planning
Safety, Housekeeping, Staff Training and Development
Minimum of 3-5 years’ experience as an injection molding Process Engineer.
High school education with advanced technical training. Bachelor’s degree preferred.
Knowledge of lean manufacturing principles and techniques.
Proficient using statistical analysis tools; Six sigma certification a plus.
Must be self-motivated, work well independently and have excellent time management skills.
Advanced knowledge of plastic injection molding machine operations, mold configuration and set-up and processing of molds and auxiliary equipment.
Advanced knowledge of a wide range of resins, processing and troubleshooting to precision tolerances.
Knowledge of manufactured products and processes.
Knowledge of measuring tools and ability to read blue prints
Ability to properly maintain records and document procedures, processes and other data.
Ability to work effectively and cooperatively with others.
Ability to train other personnel in set-up processes and trouble-shooting.
Working knowledge of computers: Word, Excel, Outlook and other applications such as Macola ES and Mattec