Molding Excellence Manager

Silgan Dispensing•Grandview, MO

9d•Onsite

About The Position

The Molding Excellence Manager owns injection molding output, process control, and molded component quality across four value streams—TS800, PreFresh, Mixor, and Radar—in a 24/7, three-shift operation. This is a process and management role for a scientific molder who leads with data and develops the team. The position is accountable for validated process windows, capable processes, and statistical discipline rather than shift-to-shift preferences. The manager owns molding Performance and Quality components of OEE; Availability, molding equipment maintenance, the injection mold tool room, and CNC machining belong to the Molding Services & Tool Room Manager. The Molding Excellence Manager is the internal customer of that center under a documented service level agreement. Direct reports include molding supervisors on all shifts, process technicians, and process engineers; molding operators and material handlers report indirectly. The role leads process control and scientific molding, production output and quality, tooling interfaces, people development, cost and resource management, and tiered management and compliance. It owns and facilitates Tier 2a, attends PLT sessions for assigned value streams, and prepares and presents the molding section at Tier 3. At least 50 percent of working time is spent on the production floor, including GEMBA participation. The position works in a general manufacturing plant environment with injection molding presses, auxiliary equipment, hydraulic systems, hot surfaces, and powered industrial trucks. Noise is usually moderate to loud, and personal protective equipment is required in designated areas. The role supports a 24/7 operation and requires availability across all three shifts, including periodic off-shift and weekend presence. Approximately 5% travel may be required.

Requirements

Bachelor's degree in Plastics, Mechanical, or Manufacturing Engineering, or an equivalent combination of education and directly applicable scientific molding experience.
At least seven years of progressive injection molding experience in a high-volume, multi-cavity, multi-press environment.
At least three years leading salaried supervisors or engineers.
Demonstrated ownership of molding OEE and scrap, with a documented baseline, countermeasures applied, and measured results.
Experience in an ISO 9001 and ISO 14001 certified facility, including participation in third-party audits.
Experience in a 24/7 continuous operation with responsibility spanning all shifts.
Required scientific/decoupled molding expertise: rheology studies, cavity pressure and gate seal studies, cooling and cycle optimization, and development and validation of process windows.
Ability to personally apply statistics, including control charts, capability studies, Cpk, measurement system understanding, and design of experiments.
Knowledge of mold construction, hot runner systems, and mold condition assessment sufficient to diagnose and prove whether defects originate in the tool, machine, process, or material.
Knowledge of resin drying, purge discipline, regrind handling, and color changeover standard work.
Use of A3, 5-Why, and fishbone as routine problem-solving methods.
Ability to use ERP systems and advanced Excel; ability to read and interpret safety rules, operating and maintenance instructions, engineering drawings, mold and part prints, and process sheets.
Ability to write routine reports and corrective action responses and present data and recommendations to plant and corporate leadership, customers, and auditors.
Ability to calculate and interpret rates, ratios, percentages, OEE, cycle efficiency, scrap and yield rates, and cost per thousand pieces.
Ability to apply statistical methods including mean, range, standard deviation, control limits, and capability indices, and interpret control charts correctly.
Ability to define problems, collect data, establish facts, draw valid conclusions, distinguish signal from noise, and withhold action when data does not support it.
Demonstrated self-direction, accountability for departmental performance, data transparency, sound judgment in leaving stable processes alone, and coaching and development of supervisors and process technicians.
Availability across all three shifts, including periodic off-shift and weekend presence.
Ability to perform the physical duties described, with reasonable accommodation where applicable; color vision is essential for evaluating resin and color defects.

Nice To Haves

RJG Master Molder or equivalent scientific molding certification.
Lean Six Sigma Green Belt or higher.
Formal TPM implementation experience.
Packaging, dispensing, or closures molding experience.
Mold flow simulation experience.
Budget ownership experience.
JD Edwards EnterpriseOne experience.

Responsibilities

Establish and enforce documented, scientifically developed and validated process windows for every mold, including rheology, cavity pressure, gate seal, cooling, and cycle optimization.
Own process capability; conduct capability studies on critical characteristics and drive Cpk to target. Do not release processes that cannot be demonstrated to be capable.
Maintain XmR control charts for designated critical process outputs, distinguish special cause from common cause, respond to signals, and avoid disturbing stable processes.
Own design of experiments, process sheets, setup standards, change control, and color and resin performance in the process.
Own daily and weekly molding output against plan across all four value streams and maintain molded component coverage to Assembly.
Own the Performance and Quality components of Molding OEE, manage cycle time to standard, and track scrap separately.
Maintain current Hour-by-Hour boards, ensure honest downtime reason codes, and take action within the hour.
Own molding scrap dollars, maintain a scrap Pareto by mold and defect code, and lead A3 root cause analysis on priority issues.
Build and present the weekly molding production plan, including press and mold assignments, resin and color requirements, and required overtime.
Serve as the internal customer of the Molding Services & Tool Room center; document mold and press defects with dimensional, process, and image evidence, and prioritize repairs against production impact and dollarized capacity loss.
Verify mold condition and cavitation after service and formally accept or reject the release; do not return molds to production based on verbal approval.
Protect committed preventive maintenance windows in the production plan.
Own production-side TPM, including Autonomous Maintenance task definition, training, and daily completion verification.
Lead through supervisors and process technicians; hold and document weekly one-on-ones with each direct report.
Develop scientific molding fundamentals, troubleshooting discipline, and data literacy; build bench strength through structured cross-training and knowledge capture.
Own molding staffing, attendance management, structured 90-day onboarding, and 90-day retention.
Spend at least 50 percent of working time on the production floor and participate in GEMBA.
Own the molding labor plan and overtime forecast and submit it to the Plant Manager for approval proactively.
Own resin yield and material loss, including purge, startup scrap, and regrind handling, as well as molding energy intensity per thousand pieces.
Support capital and cost-reduction proposals with a documented baseline, quantified benefit, and stated alternatives considered.
Own and facilitate Tier 2a, ensuring every issue leaves with an owner, action, and due date; deliver the structured daily molding data package to the Plant Manager.
Prepare and present the molding section of the Tier 3 review and attend PLT sessions for assigned value streams.
Maintain molding processes, records, and work instructions in conformance with ISO 9001:2015 and ISO 14001:2015, and own molding-related corrective actions through evidenced closure.
Enforce lockout/tagout, machine guarding, and hot-surface safety requirements; promote safe conduct and environmental stewardship.
Follow all work rules and policies and perform other assigned duties.