Advanced Molding Group Process Engineer

HellermannTyton North America•Milwaukee, WI

11d•Onsite

About The Position

The Advanced Molding Group Process Engineer ensures new injection-molded parts and processes are optimized for production, generally using overall equipment effectiveness (OEE) and the ability to establish a robust processing window as measures. The engineer focuses on higher-risk projects, including parts, materials, or processes that are new to the organization or require improvement. The role researches and implements new materials and processes, participates in corrective actions and continuous improvement, and supports the policies, procedures, work instructions, and documentation needed to maintain HellermannTyton’s Quality and EHS&S certifications. The engineer works with project teams and cross-functional partners to bring projects into production at acceptable OEE and risk levels, optimize systems and processes, and recommend changes and equipment. The role also provides technical guidance and mentoring to engineers, technicians, and project teams, and assists with training needs. Successful performance requires extensive hands-on injection molding and scientific processing expertise, strong problem-solving and statistical skills, and the ability to communicate technical concepts and help others learn. The position requires a bachelor’s degree in engineering or a related technical field, or equivalent experience demonstrating progressive learning and responsibility, as well as at least five years of hands-on injection molding experience. The successful candidate is self-motivated, results-oriented, mechanically apt, proficient with CAD software and MS O365, able to manage multiple tasks independently in a fast-paced environment, and willing to travel two to four times per year. A valid driver’s license, acceptable driving record, and adequate automobile insurance are also required.

Requirements

Bachelor’s degree in engineering, 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.
Proficiency with CAD software.
Self-motivated and results-oriented.
Good technical writing skills.
Good verbal and written communication skills.
High mechanical aptitude.
Software skills, including MS O365.
Proven ability to work independently and manage multiple tasks in a fast-paced environment.
Valid driver’s license, acceptable driving record, and adequate automobile insurance.
Willingness and ability to travel 2–4 times per year.
Ability to set molds and establish robust processes on varied injection molding machines and resins using scientific injection molding.
Ability to use, evaluate, and recommend injection molding auxiliary equipment.
Knowledge of heat transfer, mold cooling, shear-induced flow, statistics, gate sizing, mold design, FEA, and flow analysis.
Ability to explain APQP and write PFMEAs; working knowledge of DFMEAs, Control Plans, SPC, and level 3 PPAPs.
Ability to explain root-cause analysis methods and coordinate analytical work.
Ability to read part drawings, preferably including GD&T, and perform basic measurements.
Ability to communicate clearly and concisely and to teach and support the learning of others.
Understanding of hygroscopic resin moisture absorption and desorption and their effects on processing and part performance.

Responsibilities

Work with others to move assigned projects into production with acceptable OEE and risk levels.
Guide and mentor process engineers, technicians, and project teams to support continuous improvement; recommend learning opportunities.
Collaborate with materials, mold tooling, and quality engineers to optimize systems and processes and promote needed changes.
Evaluate equipment and, where applicable, recommend screw geometry, non-return valves, and auxiliary equipment such as dryers and blenders.
Apply and explain root-cause failure analysis techniques; work with materials engineers to recommend analytical methods and coordinate actions with internal teams or outside laboratories.
Recommend hot runner setups.
Work with maintenance to establish appropriate 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 incorporate these practices through Control Plans and level 3 PPAPs.
Set up, run, and evaluate DOEs and make appropriate recommendations.
Assist the Director of Manufacturing in evaluating and recommending key process-related equipment.
Use scientific injection molding to set molds and establish robust processes across different injection molding machines and resins.
Use, evaluate, and recommend injection molding auxiliary equipment, including moisture analyzers, blenders, dryers, mold temperature control units, and hot runner controllers.
Explain and calculate heat transfer and recommend mold cooling requirements.
Analyze shear-induced flow groups and recommend actions for mitigating fill imbalance.
Interpret statistical tools such as Cp, Cpk, and standard deviation.
Calculate gate sizes using shear rate.
Explain mechanical mold design from a structural perspective and recommend, specify, and interpret FEA analyses.
Explain flow analyses and recommend, specify, and interpret those analyses.
Apply APQP and PFMEAs, with working knowledge of DFMEAs, Control Plans, and SPC.
Work with process engineering, automation, industrial engineers, maintenance, and other team members to implement mold pressure and temperature sensing, EOAT, vision, or other inspection systems to maximize OEE.
Read part drawings, preferably including GD&T, and perform basic measurements.
Explain and evaluate scientific injection molding practices and the effects of hygroscopic resin moisture absorption and desorption on processing and part performance.
Perform other duties as assigned.