Job Overview

The Senior Molding Engineer is the plant technical leader for injection molding process development,  optimization, and sustainment. The role drives safe, capable, stable, and cost-effective molding operations by applying scientific molding principles, robust validation methods, data analysis, and structured problem solving. This position partners closely with Operations, Quality, Maintenance, Toolroom, Product Engineering, Supply Chain, Procurement, and external suppliers to deliver new product launches, productivity improvements, defect reduction, and reliable production performance.

Job Requirements

Molding Process Development & Industrialization
•    Lead the development, qualification, transfer, and implementation of injection molding processes for new and existing products.
•    Define molding process windows, machine requirements, auxiliary equipment, tooling interfaces, material-handling methods, cycle-time targets, and production standards.
•    Lead mold and process validations, including trial planning, sampling, capability studies, acceptance criteria, documentation, and production release.
•    Apply scientific and systematic molding methods to establish repeatable processes and reduce dependence on operator adjustment.
•    Participate in DFM and tooling reviews to improve manufacturability, quality, maintainability, cycle time, and overall project risk.
•    Support equipment installation, commissioning, startup, and ramp-up through stable production.
Operational Excellence & Troubleshooting
•    Serve as a senior technical resource for complex molding, material, machine, robot, hot-runner, and tooling-related problems.
•    Lead structured root-cause analysis and corrective actions for scrap, flash, short shots, dimensional variation, cosmetic defects, cycle-time losses, downtime, and recurring process instability.
•    Drive improvements in OEE, first-pass yield, cycle time, material utilization, process capability, downtime, and labor productivity.
•    Use process data, statistics, and monitoring systems to identify variation, validate improvements, and sustain results.
•    Develop and maintain standard process setup sheets, troubleshooting guides, reaction plans, and process-control requirements.
•    Partner with Maintenance and Toolroom teams on preventive actions, mold repairs, equipment reliability, and recurrence prevention.
•    Experience with Ready to Deploy projects such as : Cycle Time Reduction, Resin Waste Reduction.
Automation, Equipment & Technology
•    Specify and implement molding cells, robots, end-of-arm tooling, dryers, material-conveying systems, temperature controllers, vision systems, and auxiliary equipment.
•    Program or support industrial robots used in molding operations, including safe sequencing, part handling, separation, and downstream integration.
Project Leadership & Plant Collaboration
•    Lead molding improvement and productivity projects from definition through implementation, validation, benefit confirmation, and closure.
•    Manage project scope, milestones, risks, actions, costs, and stakeholder communication for assigned initiatives.
•    Support capital planning and prepare technical justifications for molding equipment, automation, tooling, and auxiliary systems.
•    Coordinate effectively with Operations, Quality, Maintenance, Toolroom, EHS, Product Engineering, Supply Chain, Procurement, and external suppliers.
Standardization, Training & Technical Leadership
•    Develop, improve, and sustain plant molding standards, best practices, validation methods, and technical documentation.
•    Mentor molding engineers, technicians, setup personnel, and production support teams in scientific molding, troubleshooting, and process discipline.
•    Create and deliver technical training based on plant needs and recurring process gaps.
•    Influence cross-functional teams through technical credibility, fact-based decisions, and strong follow-through.

What your background should look like

• Bachelor's degree in Mechanical, Manufacturing, Plastics, Mechatronics, Industrial Engineering, or a related engineering discipline.
• Typically 5 or more years of hands-on experience in injection molding manufacturing, process engineering, molding equipment, or closely related operations.
• Demonstrated experience with process development, mold trials, process validation, troubleshooting, and production launch support.
• Strong knowledge of injection molding machines, thermoplastic materials, molds, hot runners, auxiliary equipment, and molding defects.
• Experience leading technical projects and coordinating cross-functional implementation activities.
• Proficiency with Microsoft Office and working knowledge of manufacturing systems such as SAP or equivalent.
• Professional English communication skills for technical documentation, supplier interaction, and cross-site collaboration.
• Scientific or systematic molding certification, including RJG Master Molder I.
• Experience with SolidWorks, Creo, or other 3D CAD software.
• Robot programming experience with Wittmann, Yushin, or comparable platforms.
• Valid passport and ability to travel domestically or internationally as business needs require. 
• Working knowledge of mold construction, maintenance, wear mechanisms, cooling, venting, gating, and repair methods.
• Six Sigma, DOE, SPC, MSA, capability analysis, or advanced problem-solving experience.