Senior Engineer - Process

Responsibilities: Product Design & Development: Collaborate with product development teams to design and optimize plastic components for manufacturability, performance, and cost-effectiveness. Apply principles of DFM (Design for Manufacturability) to ensure robust and efficient production. Understand CAD software to review 3D models and 2D drawings of plastic parts and assemblies. Tooling Design & Optimization: Work closely with toolmakers and suppliers to define, design, and procure injection molds. Review and approve mold designs, ensuring adherence to specifications, quality standards, and production requirements. Lead the development and procurement of prototype tooling, evaluating different tooling approaches for early-stage product validation. Identify and implement improvements to existing tooling for enhanced performance, longevity, and reduced cycle times. Injection Molding Process Development & Optimization: Oversee set up, operation, and troubleshooting of injection molding presses to achieve optimal part quality and production efficiency. Develop and refine molding parameters (temperatures, pressures, cycle times, etc.) for various plastic resins. Conduct root cause analysis for molding defects and implement corrective actions. Perform process validation and qualification activities. Mold Flow Analysis: Utilize mold flow simulation software (e.g., Moldflow, SolidWorks Plastics) to predict and optimize material flow, cooling, warpage, and other molding phenomena. Interpret simulation results to guide part and tool design decisions, minimizing potential molding issues. Supplier Management & Performance: Oversee and manage external injection molding suppliers to ensure consistent quality, on-time delivery, and adherence to specifications. Conduct supplier audits, assess capabilities, and drive continuous improvement initiatives with suppliers. Act as the primary technical liaison with molding suppliers, resolving technical issues and ensuring optimal performance. Evaluate supplier performance metrics and implement strategies to enhance overall supplier relationships and output. Plastics Material Selection & Characterization: Research, evaluate, and recommend appropriate plastic resins and compounds based on product requirements, performance specifications, environmental considerations, and cost constraints. Possess a deep understanding of the properties, processing characteristics, and applications of various thermoplastic and thermoset materials. Conduct material testing and characterization to validate performance and ensure suitability for specific applications. Quality Assurance & Continuous Improvement: Develop and implement quality control plans for plastic components. Participate in FMEA (Failure Mode and Effects Analysis) and other quality improvement initiatives. Identify and implement opportunities for…