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Sr. Thermoforming Process Engineer

Requisition ID:  9322
Location:  27526, NC, US, 27526
Alternative Locations: 
Education Experience:  Bachelors Degree (High School +4 years)
Employment Experience:  1-3 years
Travel:  None


Company Information

TE Connectivity Ltd., is a $13 billion global technology and manufacturing leader creating a safer, sustainable, productive, and connected future. For more than 75 years, our connectivity and sensor solutions, proven in the harshest environments, have enabled advancements in transportation, industrial applications, medical technology, energy, data communications, and the home. With 78,000 employees, including more than 7,000 engineers, working alongside customers in nearly 150 countries, TE ensures that EVERY CONNECTION COUNTS. Learn more at and on LinkedInFacebookWeChat and Twitter.

TE's Energy business unit, part of the Industrial Solutions segment, offers a wide range of reliable and cost-effective products for the electrical power industry. Our position as a leading supplier of electrical components enables us to design next-generation products. For over 60 years, we have worked closely with our customers around the globe to develop innovative solutions to ever-changing challenges, known under names such as Axicom, Crompton Instruments and Simel. Some of the industries that we serve include energy generation, distribution, and transmission.

Job Overview

The Energy business unit in Fuquay-Varina, North Carolina is seeking a Thermoforming Mold Design and Process Engineer to support both existing and new process development/improvement activities.  The primary focus will be utilizing technical expertise to ramp up Thermoforming Production.  In addition, responsibilities include sustaining existing heavy gauge plastic thermoformed parts for the Energy industry and supporting rapid prototyping for new products.  The ideal candidate will be able to take a part drawing, create a detailed CAD drawing of a mold, oversee machining of the mold, and successfully prototype/ramp up the new part.  They will also use project management skills to implement Thermoforming on site, and then continue to identify and execute cost savings in material, labor, and scrap. TEGTA16

Responsibilities & Qualifications


  • Manage existing project to ramp up capabilities to a site that does not currently have Thermoforming Process experience
  • Work closely with Product Management, Maintenance, and R&D to rapidly respond to new product requests and Production issues
  • Prepare detailed mechanical drawings of molds based on part drawings
  • Create Bills of Material for new parts and modify them for existing parts.
  • Improve Thermoforming process through Statistical Process Control
  • Document and optimize process parameters such as run sheets, standard work instructions, and quality inspection plans
  • Reduce scrap through the use of process improvement tools such as Quick Changeover, QCPC, and layout optimization
  • Work with other disciplines within the plant to develop accurate specifications and documentation to support new product introduction with focus toward manufacturability
  • Initiate justifications for capital expenditures
  • Project manage large and small capital projects efficiently to complete on time and within budget



  • Minimum BS degree in Engineering or Engineering Technology (Mechanical or Manufacturing Preferred)
  • 7+ years of experience in a heavy gauge plastic thermoforming manufacturing environment supporting production and new product introductions.
  • 7+ years of experience designing and troubleshooting thermoforming molds.
  • Proven track record in the application and use of LEAN/Six Sigma tools
  • Demonstrated Project Management skills to execute cost reduction projects on time and within budget
  • Proficiency in 3D or 2D modeling software for mold design required, experience in Creo is a plus
  • Experience with ERP system set up and use is a plus (SAP and/or MFGPRO)
  • Six Sigma Green Belt or Black Belt is preferred
  • Individual should be:
    • a self-starter with the ability to work in a fast change, high paced environment
    • able to work across functions to achieve results
    • able to manage changing priorities
    • able to understand business needs
    • a team player


  • Values: Integrity, Accountability,Teamwork, Innovation
  • Action Oriented
  • Communication
  • Computer Skills
  • Problem Solving
  • Results Focus
  • Teamwork

Nearest Major Market: Raleigh

Job Segment: Process Engineer, Thermal Engineering, Manufacturing Engineer, Engineer, Electrical, Engineering

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