Process Engineer

Job Title: Process Engineer

Work Location: Lynchburg County, Virginia

Summary:

Seeking a Process Engineer to drive the development, validation, and optimization of injection molding processes, with a focus on troubleshooting, process improvement, and cross-functional collaboration in a regulated manufacturing environment.

Responsibilities:

• Develop and maintain robust injection molding processes, including process validation, documentation, and troubleshooting of molding defects.
• Lead new mold trials, process development, sampling, and production launch activities, ensuring process windows are established using scientific molding principles.
• Perform process studies such as fill analysis, gate-seal studies, pressure-loss studies, and cooling evaluations to optimize process parameters.
• Provide urgent technical support for process instability or equipment downtime, ensuring machines are returned to approved settings after troubleshooting or maintenance.
• Reduce scrap, downtime, cycle time, and unplanned process adjustments while maintaining product quality and equipment reliability.
• Analyze process data, trends, scrap reports, and production metrics to support continuous improvement and corrective actions.
• Collaborate with cross-functional teams and train/mentor technical staff, promoting standardized and documented technical practices.
• Ensure compliance with safety, quality, and regulatory requirements, and participate in audits and installation/qualification activities as needed.

Qualifications:

• Associate or bachelor’s degree in Plastics Engineering, Manufacturing Engineering, Mechanical Engineering, or related technical field; equivalent hands-on experience may be considered.
• Three to five years of injection molding process development or process engineering experience.
• Strong understanding of thermoplastic materials, drying requirements, material handling, mold construction, cooling systems, hot runners, and auxiliary equipment.
• Ability to independently troubleshoot complex molding and tooling problems.
• Experience with hydraulic, electric, or hybrid injection molding machines.
• Ability to interpret part drawings, specifications, tolerances, process data, and quality requirements.
• Working knowledge of statistical process control, process capability, root-cause analysis, and structured problem-solving.
• Ability to work directly on the production floor and respond urgently to technical problems.
• Strong written, verbal, organizational, and interpersonal skills.
• Working knowledge of Microsoft Office and manufacturing ERP or production-monitoring systems.
• Preferred: Experience with blow molding (extrusion, injection, or stretch), parison programming, wall-thickness control, and troubleshooting blow molding issues.
• Preferred: RJG, Paulson, AIM Institute, or equivalent scientific-molding training; experience with RJG eDART or similar process-monitoring technology.
• Preferred: Experience in regulated manufacturing (medical device, aerospace, automotive), IQMS or DELMIAWorks, automation, robotics, vision systems, and secondary operations.
• Preferred: Experience conducting DOE, Gage R&R, capability studies, and molding process validations; Lean manufacturing, Six Sigma, or continuous-improvement experience.
• Ability to work in an active manufacturing environment, stand/walk for extended periods, climb/bend/reach, lift up to 50 pounds, and provide technical support across shifts as needed.
• Required use of applicable personal protective equipment.

Published Category: Manufacturing & Technical Operations