Process Technician

Job Title: Process Engineering Technician

Industry: Plastics Manufacturing

On-site Location: Montgomery, AL

Relocation Provided: Possibly

Hourly Range: $25+++ Depending on experience

Job Overview:

The Injection Molding Process Engineer is a critical, hands-on technical role responsible for developing, optimizing, and sustaining robust injection molding processes in a high-volume, automotive-grade manufacturing environment.

This position plays a key role in stabilizing production, reducing scrap, improving cycle times, and supporting new mold and program launches. The engineer will work directly on the production floor, troubleshooting issues in real time and ensuring process repeatability for complex, appearance-critical components.

Success in this role requires strong ownership, practical problem-solving skills, and comfort working in a fast-paced, highly automated environment with minimal tolerance for downtime.

Minimum Requirements:

• 3+ years of hands-on injection molding process engineering experience in a manufacturing environment
• Strong troubleshooting capability with direct machine/process adjustments (not purely theoretical)
• Experience with injection molding, including:
  • Appearance (Class A) surfaces
  • Two-shot molding
  • Mold-in-color processes
• Experience with a variety of tonnage presses (400-2000)
• Exposure to automation systems, including:
  • Robotics
  • End-of-arm tooling (EOAT)
  • Integrated downstream processes (trimming, inspection, assembly)
• Experience with Lean Manufacturing, 5S, and Six Sigma methodologies
• Knowledge of engineering resins (PA, PC, ABS, PP, glass-filled materials, specialty resins)
• Strong understanding of scientific molding principles and process validation
• Ability to read and interpret part drawings, GD&T, and technical specifications
• Comfortable working in a fast-paced, production-driven, less structured environment
• Ability to independently solve problems under pressure on the production floor
• Proficiency with Microsoft Office (Excel, Word, PowerPoint)

Preferred Requirements:

• Automotive Tier 1 manufacturing experience
• Experience with Engel injection molding machines
  
• ERP or production tracking system experience
  

Responsibilities:

Process Development & Optimization

• Develop and establish injection molding process parameters using scientific molding principles
• Lead mold trials, validations (T0–T3), and capability studies
• Optimize cycle times, scrap rates, and machine efficiency (OEE)
• Establish standardized startup and shutdown procedures
• Ensure processes meet strict dimensional and cosmetic specifications

Production Support & Troubleshooting

• Provide hands-on support for molding operations across a wide tonnage range
• Diagnose and resolve defects such as:
  • Flow lines, sink, gloss variation, and weld lines
  • Short shots, flash, splay, burn marks, warp, and dimensional instability
• Respond to downtime events and lead root cause analysis
• Collaborate with maintenance on equipment, hot runner, and auxiliary issues
• Support off-shift teams during critical production issues

New Program Launch & Tooling Support

• Support design for manufacturing (DFM) reviews
• Provide input on mold design (gating, venting, cooling, ejection)
• Lead first article runs and PPAP submissions
• Coordinate mold trials, transfers, and qualifications

Automation & Integration

• Support and optimize interaction between molding processes and automation systems
• Ensure process changes align with robotic performance and downstream operations
• Assist with the setup and troubleshooting of automation systems

Continuous Improvement

• Drive scrap reduction and cost improvement initiatives
• Lead cycle time reduction projects without compromising quality
• Analyze process data and implement structured problem-solving methods
• Support Lean, 5S, and Six Sigma initiatives

Documentation & Compliance

• Maintain process sheets, setup documentation, and standardized work instructions
• Ensure compliance with customer, quality, and regulatory standards
• Support audits and maintain validation and engineering change records