What are the responsibilities and job description for the Senior Process Engineer position at Theoris?
The Senior Process Engineer is responsible for leading the planning, development, validation, and optimization of processes related to molding operations. This role works closely with cross-functional teams to ensure successful execution of trials, integration of new molds, and continuous improvement initiatives. Additionally, the Process Engineer serves as a technical expert, driving design for manufacturability (DFM), ensuring process standardization, and supporting business development.
KEY PERFORMANCE OBJECTIVES:
- Process Development and Validation. Acts as the lead subject matter expert of process development and molding validation, ensuring robust injection molding processes are established and delivered to production.
- DFM and Business Development Support. Serves as the face of injection molding to the customer and contributes to the overall success of new business growth.
- Planning and Scheduling. Functions as a primary contributor to the overall success of customer project timelines by ensuring mold validation trials are scheduled and accomplished to plan.
- Process Standardization and Continuous Improvement. Leads the systemization and continuous improvement of the plastic injection molding process to ensure stable and predictable production.
ESSENTIAL DUTIES AND RESPONSIBILITIES:
The responsibilities listed are fundamental to the position and must be performed successfully to achieve the key performance objectives of the role. Other responsibilities may be assigned.
- Partners with Project Managers to oversee and execute mold validation processes, ensuring alignment with established protocols.
- Utilizes quality protocols to conduct mold validations, documenting results for the Quality Engineer while providing insights for process development and improvement based on inspection data.
- Travels to vendor or tool shops to observe initial mold trials, provide feedback for optimization, and approve tooling adjustments for production compatibility.
- Identifies and communicates necessary tooling adjustments during validations, coordinating with the Tooling Engineer to address issues.
- Analyzes mold flow analysis data to establish and refine molding process parameters.
- Supports the Manufacturing Engineering team in integrating mold machines, robotics, and material handling systems to optimize production.
- Collaborates on the integration of online inspection systems with molding machines, ensuring proper signal communication for part rejection and data accuracy.
- Ensures equipment readiness, availability of machines, and allocation of manpower to support trial execution.
- Trains and guides molding managers and team members to prepare equipment, molds, and materials for successful trials.
- Addresses tooling maintenance requirements during trials, coordinating adjustments and repairs with the maintenance team and submitting work orders as needed.
- Provides recommendations for mold maintenance schedules based on trial data and observations.
- Oversees equipment maintenance during trials, ensuring compatibility and optimal performance through repairs and adjustments.
- Coordinates with metrology labs for dimensional analysis of samples, using feedback to refine process parameters.
- Works closely with material suppliers to identify and implement process improvements that enhance material compatibility and performance.
Requirements
- A disciplined, autonomous professional who is able to successfully manage time and priorities
- A collaborative team member who will partner with others to achieve our mission
- A self-motivated learner who will research and institute departmental best practices
- Demonstrated record of introducing new injection molding processes & technologies.
- Track record of successful problem-solving for the production of plastic parts using structured, Scientific Molding methods to develop effective solutions.
- Experience with RJG / E-Dart Decoupled 3 process
- Strong computer skills – Microsoft Office / ERP System experience
- Excellent written and verbal communication skills
