Injection Molding Process Engineer
Job Summary
The Injection Molding Process Engineer is responsible for developing, optimizing, and troubleshooting injection molding processes to ensure consistent production of high-quality plastic components. This role works closely with tooling, quality, and production teams to establish robust process parameters, resolve defects, and drive continuous improvement initiatives across the molding floor.
Key Responsibilities
- Develop, document, and validate injection molding process parameters for new and existing tools, including scientific molding setups (fill, pack, hold, cooling profiles).
- Conduct mold trials, DOEs (Design of Experiments), and process capability studies to establish robust, repeatable processes.
- Troubleshoot and resolve molding defects such as short shots, flash, warpage, sink marks, voids, splay, and dimensional variation.
- Optimize cycle times, scrap rates, and material usage to improve productivity and cost efficiency.
- Create and maintain process documentation including process sheets, setup sheets, control plans, and PFMEAs.
- Collaborate with tooling engineers on mold design, modifications, and preventive maintenance to support process stability.
- Support new product introduction (NPI) by working with design teams on DFM (Design for Manufacturability) feedback.
- Perform material selection and characterization in coordination with materials engineering.
- Lead root cause analysis and corrective action efforts (8D, fishbone, 5-Why) for quality escapes.
- Train and support production operators and technicians on process standards and best practices.
- Utilize statistical process control (SPC) and data analysis tools to monitor process stability and drive improvements.
- Support equipment selection, qualification, and preventive maintenance programs for injection molding machines and auxiliary equipment.
Required Skills and Qualifications
- Bachelor's degree in Mechanical, Plastics, Manufacturing, or Materials Engineering (or equivalent practical experience).
- 3+ years of hands-on experience in injection molding process engineering or a closely related role.
- Strong understanding of scientific molding principles and thermoplastic material behavior.
- Experience with mold sampling, first-article inspection, and process validation (IQ/OQ/PQ).
- Proficiency in reading and interpreting mold drawings, part prints, and GD&T.
- Familiarity with SPC, Cpk/Ppk analysis, and statistical software (e.g., Minitab) is a plus.
- Working knowledge of auxiliary equipment: hot runners, robots, dryers, chillers, and material handling systems.
- Experience troubleshooting common molding defects and applying corrective process adjustments.
- Strong analytical and problem-solving skills with a data-driven approach.
- Excellent communication skills, with the ability to work cross-functionally with tooling, quality, and production teams.
- Proficiency with process monitoring software/systems (e.g., RJG, CoMo, or equivalent) preferred.
- Knowledge of ISO 9001/IATF 16949 quality systems is a plus, especially in automotive or medical device manufacturing environments.
- Ability to work on the production floor and travel occasionally for mold trials at supplier locations.
Pay: ₹20,000.00 - ₹25,000.00 per month
Work Location: In person
