Advanced Molding Group Process Engineer

Hellerman Tyton•Milwaukee, WI

1d•Onsite

About The Position

The Advanced Molding Group Process Engineer ensures that new injection-molded parts and processes are optimized for production, using measures such as Overall Equipment Effectiveness (OEE) and the ability to establish a robust processing window. The role focuses on higher-risk projects involving parts, materials, or processes that are new to the organization or require improvement. It also involves researching and implementing new materials or processes and participating in corrective actions and continuous improvement while supporting corporate policies, procedures, work instructions, documentation, and HellermannTyton's Quality and EHS&S certifications. The engineer works across project and technical teams to bring projects into production at acceptable OEE and risk levels; mentors process engineers and technicians; and collaborates with materials, mold tooling, quality, maintenance, automation, industrial engineering, and other functions. The role includes evaluating molding equipment and processes, applying root-cause analysis and statistical methods, supporting APQP and related quality planning, setting up and evaluating DOEs, and advising on process-related equipment and training needs. Success requires extensive hands-on injection molding knowledge, including scientific injection molding across machines and resins, molding auxiliaries, heat transfer and cooling, shear-induced flow, mold and flow analysis, process monitoring and inspection systems, and part measurement. The engineer is expected to communicate clearly, support others' learning, work independently, manage multiple tasks, and travel two to four times per year.

Requirements

Bachelor's degree in engineering or a related technical field, or experience demonstrating progressive learning and responsibility.
At least 5 years of hands-on injection molding experience with a proven understanding of successful injection molding.
Ability to set a mold and establish robust processes on a variety of injection molding machines and resins using scientific injection molding.
Ability to use, evaluate, and recommend injection molding auxiliary equipment, including moisture analyzers, blenders, dryers, mold temperature control units, and hot runner controllers.
Ability to explain, calculate, and recommend mold cooling requirements and to assess shear-induced flow and fill-imbalance mitigation.
Ability to interpret statistical tools such as Cp, Cpk, and standard deviation, and calculate gate sizes using shear rate.
Ability to explain mechanical mold design from a structural perspective and recommend, specify, and interpret FEA analyses.
Ability to explain flow analyses and recommend, specify, and interpret them.
Ability to explain APQP, write PFMEAs, and demonstrate working knowledge of DFMEAs, Control Plans, and SPC.
Knowledge of mold pressure and temperature sensing, EOAT, vision, or other inspection systems.
Ability to read part drawings, preferably including GD&T, and perform basic measurements.
Understanding of hygroscopic resin moisture absorption and desorption, and the effects of resin moisture on processing and part performance.
Ability to explain and evaluate scientific injection molding practices.
Proficiency with CAD software and software skills including MS O365.
Self-motivated, results-oriented, and mechanically apt, with good technical writing and verbal and written communication skills.
Ability to work independently and manage multiple tasks in a fast-paced environment.
A teachable point of view and the ability and aptitude to help others learn.
Valid driver's license with an acceptable driving record and adequate automobile insurance.
Willingness and ability to travel two to four times per year.

Responsibilities

Work with others to bring assigned projects into production with acceptable OEE and risk levels.
Provide guidance and mentoring to process engineers, technicians, and project teams to support continuous improvement; recommend learning opportunities.
Collaborate with materials engineers, mold tooling engineers, and quality engineers to optimize systems and processes and promote change where needed.
Evaluate equipment and, where applicable, recommend screw geometry, non-return valves, auxiliary equipment, and hot runner setups.
Use and explain root-cause failure analysis techniques; work with the materials engineer to recommend analytical methods and coordinate actions internally or with outside laboratories.
Work with maintenance to establish preventive maintenance cycles for presses and equipment.
Assist the Director of Manufacturing and Training Department in evaluating training needs for Process Engineers and Process Technicians.
Explain APQP, write and evaluate PFMEAs, and support their incorporation into Control Plans and level 3 PPAPs.
Set up, run, and evaluate DOEs and make recommendations as needed.
Assist the Director of Manufacturing in evaluating and recommending key process-related equipment.
Work with process engineering, automation, industrial engineering, maintenance, and other team members to implement strategies for maximizing OEE.
Perform other duties as assigned.