Manufacturing Engineer - Compression Molding & Plastics Processing

POSITION SUMMARY:

The Manufacturing Engineer is responsible for developing, optimizing, and sustaining manufacturing processes, with primary emphasis on compression molding and plastics processing. This hands-on role combines process development, technical problem solving, and continuous improvement to enhance safety, quality, delivery, productivity, and profitability.

The engineer will work closely with production, maintenance, quality, tooling, suppliers, and customers to improve molding processes, introduce new products and materials, troubleshoot manufacturing challenges, and support capital and automation projects. Experience with compression molding, polymer materials, tooling, and process validation is strongly preferred.

PRIMARY RESPONSIBILITIES:

Compression Molding & Plastics Processing

Develop, optimize, document, and sustain compression molding processes for thermoplastic components.
Establish and maintain process parameters and operating windows, including temperature, pressure, time, material preparation, cooling, and other applicable variables.
Troubleshoot molding defects, dimensional variation, material flow concerns, surface conditions, cycle inconsistency, and process instability.
Lead mold and process trials, process validation, capability studies, and production readiness activities for new and existing products.
Partner with tooling resources and suppliers to assess mold condition, improve tool performance, and address maintenance or design concerns.
Evaluate thermoplastic resins, reinforcements, additives, and other polymer-based materials for performance, processability, quality, and cost.
Develop practical standards for material handling, setup, startup, shutdown, changeover, and process control.
Process Improvement & Technical Problem Solving

Analyze production, scrap, downtime, cycle-time, and quality data to identify improvement opportunities and verify results.
Lead structured root cause investigations and corrective actions using appropriate problem-solving tools.
Plan and execute process trials and Design of Experiments (DOE) to understand critical variables and establish robust processes.
Apply Lean Manufacturing, Six Sigma, standard work, error-proofing, and waste-reduction methods to improve operational performance.
Establish and monitor key process indicators, control methods, and process capability metrics such as Cp and Cpk.
Production, Equipment & Tooling Support

Lead capital improvement projects from concept through implementation, including equipment and tooling specification, justification, supplier selection, installation, and startup.
Identify opportunities to improve safety, quality, capacity, productivity, and cost through equipment, tooling, automation, and process improvements.
Develop project scopes, budgets, timelines, and technical requirements for capital investments.
Coordinate equipment and tooling installations with production, maintenance, suppliers, and contractors to ensure successful implementation.
Provide technical support for manufacturing equipment and tooling, including troubleshooting, reliability improvements, and performance optimization.
New Product & Material Launches

Collaborate with cross-functional teams to translate customer and product requirements into capable manufacturing processes.
Support manufacturability reviews, prototype builds, tooling development, material qualifications, production trials, and launch readiness.
Develop process documentation and training needed for successful transfer into routine production.
Support APQP, PPAP, PFMEA, Control Plans, measurement planning, and other customer-specific launch requirements as applicable.
Other Manufacturing Processes

Provide engineering support for extrusion coating, laminating, web handling, converting, die-cutting, and assembly operations as business needs require.
Apply common process-control and continuous-improvement principles across manufacturing technologies.
Quality, Safety & Documentation

Ensure process changes and engineering activities support product specifications, customer requirements, and applicable quality-system requirements.
Develop and maintain setup sheets, process specifications, standard operating procedures, work instructions, and technical records.
Participate in internal and external audit support and corrective action activities.
Integrate safety, ergonomics, environmental considerations, and risk reduction into equipment and process decisions.
Train operators, technicians, and other employees on new or revised processes, equipment, and standards.
EDUCATION & EXPERIENCE

Bachelor's degree in Plastics, Polymer, Manufacturing, Mechanical, Chemical, Industrial Engineering, or a related technical field preferred.
An associate degree, technical credential, or equivalent combination of education and directly relevant manufacturing experience may be considered.
Approximately 2 or more years of manufacturing engineering, process engineering, plastics processing, tooling, or related experience preferred. Candidates with strong co-op, internship, or technician experience may also be considered.
PREFERRED TECHNICAL QUALIFICATIONS

Hands-on experience with compression molding, transfer molding, thermoforming, injection molding, or a closely related plastics process. Compression molding experience is strongly preferred.
Working knowledge of thermoplastic materials, including polyethylene, polypropylene, TPO, PET, engineered resins, additives, reinforcements, and recycled-content materials.
Understanding of how material properties, moisture, temperature history, pressure, cooling, tooling, and cycle conditions affect molded-part performance.
Experience diagnosing molding defects, dimensional concerns, cosmetic conditions, material variation, and process instability.
Experience with process validation, DOE, statistical analysis, process capability, measurement systems, and data-based decision making.
Familiarity with APQP, PPAP, PFMEA, Control Plans, ISO 9001, and IATF 16949 is preferred.
Experience with Lean Manufacturing, Six Sigma, TPM, or other continuous improvement systems.
Proficiency with Microsoft Office. Experience with CAD, Minitab, ERP/MES systems, automation, robotics, or controls is a plus.
Experience with extrusion coating, laminating, film converting, web handling, or die-cutting is beneficial but secondary to plastics molding experience.
WORK ENVIRONMENT & PHYSICAL EXPECTATIONS:

This position regularly works in an office and active manufacturing environment. The role requires frequent interaction with production equipment and employees on the manufacturing floor. Reasonable accommodations may be made to enable qualified individuals to perform the essential functions of the position.

COMPENSATION & BENEFITS:

$XX,XXX to $XX,XXX annual salary range, based on qualifications and experience.
401(k) with matching contributions.
Health and life insurance.
Short-term and long-term disability insurance.
Paid vacation and community service days.