Staff Manufacturing & Process Development Engineer (Injection Molding)

Job Overview

Process leader for molding related topics ensuring the tools and processes at Outside Vendors are running at optimum levels for quality and output. Possess extensive knowledge of mold design and tooling and the associated manufacturing processes which may include the optimization and standardization of molding processes within the manufacturing environment. Aligns with TE BU plants to reach TEOA requirements, rolls out CoE and Best Demonstrated Practices (BDP’s) and works with OV’s on tool corrections and improvements. Acts as interface between the OV’s and TE’s engineering, quality, procurement, and manufacturing/production teams. Support OV’s with tool design improvements to maintain quality standards. Ensures manufacturability of new designs and smooth production ramp up. Support research and development teams to produce engineering change samples, execute cycle time or material waste improvement projects, alternate material samplings, facilitate mold transfers, etc.

Role requiremets:

• Provide tooling and process support for molds running production at Outside Vendors. Types of molds include thermoplastic injection molds (high priority), HCR & LSR (seal) molds, and diecast molds.
  
• Create RFQ’s and enter SAP PR’s for repairs, spare tooling, engineering changes, etc. on molds at OV’s.
  
• This candidate would provide detailed support and evaluation of equipment, molds and auxiliary equipment for new and/or existing product and processes released or transferred to outside molding vendors.
  
• Work with product engineers and customers on refining the plastic part design to achieve or improve manufacturability.
  
• Utilize engineering tools for troubleshooting mold and process issues such as MoldFlow to optimize gate location, melt delivery system, and TIPM to compensate for warpage and shrinkage effects.
  
• Utilize advance cooling technologies like DMLS cooling cores/blocks, high heat transfer materials, etc to achieve required cycle times as needed.
  
• Work with Process Engineers to develop and optimize the molding processes on molds using SIM principles and cavity pressure transducer technology.
  
• Analyze & interpret CT Scan data of molded parts using Volume Graphics software. Disposition and prepare conditioning plans & direct mold suppliers to correct non-conforming dimensions on molds until they meet product drawing and PV test requirements.
  
• Work with other engineering disciplines on the team to ensure all product requirements are met and / or customer complaints are closed.
  
• Work with Quality Engineering to review the Process Flow, PFMEA, Control Plans, and ensure that Supplier QIP’s are robust.
  
• Advise and Direct Process and Tooling Technicians at OV’s on process and tooling related issues that need to be addressed.
  
• Accept release of new molds from Launch engineering and serve as the Sustaining Engineering after all product specifications have been met.
  
• Participate in mold design reviews with internal and external mold tooling suppliers facilitated by launch mold engineering.
  
• Some travel required.
  

What your background should look like:

• Bachelor’s Degree in Engineering - Plastics or Manufacturing preferred
  
• Certified RJG Master Molder I and II preferred
  
• 5+ years’ experience in injection molding; 3+ years in Automotive industry
  
• Detailed hands-on knowledge of injection molding processes
  
• Knowledge of Hot Runner systems
  
• Experience or in-depth knowledge with tooling construction processes (mills, grinders, Wire EDMs, Sinker EDMs).
  
• Automotive connector mold and molding experience preferred
  
• Must understand and utilize SIM – Scientific Injection Molding for process development.
  
• Must have hands-on knowledge of mold designs that are equipped with pressure sensors.
  
• Proficient computer skills (email, word processing, spreadsheets, presentations).
  
• Proficient in PTC Creo or SolidWorks utilizing 3D modeling capabilities: Working knowledge and experience with Part, assembly, and drawings.
  
• Effective problem-solving skills
  
• Effective communications skills (oral & written)
  
• Must be proficient in the English language.

Competencies