Process Engineer - Plastics
Listed on 2026-03-11
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Engineering
Manufacturing Engineer, Process Engineer
Position Title
Process Engineer
Wage$80,000 - $100,000/year
Accelerate Professional Talent Solutions has a great opportunity available for a Process Engineer at a company in Rockford, IL. This is a direct hire position. Apply now!
The Process Engineer is responsible for the development, optimization, and troubleshooting of all plastic injection molding processes to ensure efficient, high-quality, and consistent production. This role serves as a technical leader, working closely with Process Technicians, Tool Room personnel, and Quality teams to improve cycle times, reduce scrap, and increase overall efficiency. The position is critical for supporting new product introductions and equipment upgrades within a high-speed, thin-wall packaging environment.
ProcessEngineer Responsibilities
- Develop and document scientific injection molding processes for both new and existing molds
- Lead process validation activities, including DOE (Design of Experiments), IQ/OQ/PQ protocols, and capability studies
- Analyze process data to implement improvements that reduce cycle times and scrap rates
- Ensure all processes comply with safety, environmental, and regulatory standards (GMP/SQF)
- Partner with Tooling and Maintenance to resolve part defects and evaluate mold performance
- Provide hands‑on technical support to Molding Operators and Technicians
- Support predictive and preventive maintenance strategies to improve machine uptime and reliability
- Integrate high‑speed molding cells with robotics, vision inspection, and downstream high‑speed packaging systems
- Assist in the selection, installation, and commissioning of new injection molding machines and auxiliary equipment
- Implement automation strategies to optimize labor and improve flow
- Lead Lean Manufacturing and Six Sigma initiatives to improve OEE (Overall Equipment Effectiveness)
- Utilize Six Sigma Project Charters to drive significant cost savings and waste reduction
- Conduct labor studies and process capability analysis to ensure peak manufacturing performance
- Bachelor's Degree in Plastics, Mechanical, or Manufacturing Engineering (or equivalent professional experience)
- 5+ years of practical experience in plastic injection molding
- Experience in high‑speed, thin‑wall packaging with extremely fast cycle times
- Proven ability to develop scientific molding processes from the ground up
- Experience with RJG technology or formal scientific molding training is highly preferred
- Proficiency in SPC (Statistical Process Control) and root cause analysis
- Six Sigma Green Belt preferred; experience leading a significant cost‑saving project is required
- Proficient in Microsoft Office; familiarity with ERP and MES systems
- Deep knowledge of polypropylene, polyethylene, and thin‑wall resins (shrinkage, flow, and cooling behavior)
- Ability to read control charts and improve process capabilities
- Strong understanding of OEE tracking and improvement strategies
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