Process Development Engineer

Stone Plastics & Manufacturing•Zeeland, MI

13h

About The Position

The Process Development Engineer ensures each new mold is proven capable, stable, and repeatable before release to Production. As the technical owner of sampling and the molding process during launch, the role turns new tooling into a validated, documented process that Production can run consistently. The Process Development Engineer partners with the Launch Engineer, who owns the overall launch and APQP template, and hands off proven processes to production Process Engineers. The role engages before a tool arrives, supporting feasibility and mold-flow review, preparing DOE plans, and confirming press, material, and auxiliary-equipment readiness. When tooling arrives, the engineer prepares the mold, runs the RMT, executes DOE runs and analysis, and establishes the process window. The engineer owns launch molding parameters, consistency, and machine and peripheral equipment, including dryers, TCUs, hot-runner controls, and robotics. The Process Development Engineer conducts confirmation and follow-up sampling, requests temporary master approval, and supports capability, run-at-rate, and PPAP activities. The role leads packaging tests, coordinates workstation setup with Production, and confirms final pack quantity in X2. It works with the Manufacturing Engineer on the complete cell setup and collaborates with the Launch Engineer, Tooling, Metrology, and Quality to troubleshoot dimensional and cosmetic issues and distinguish process issues from tool issues. At the capable-part and validation run, the engineer saves the stable process, completes machine, robot, and HAL setups, creates the mold documentation book, and supports the PFMEA and control plan. At close, the engineer confirms cycle time against the quote and transfers the process to production Process Engineers. Success is measured by validated process sheets and setup documentation that enable Production to run each mold consistently. Regular and consistent attendance is required.

Requirements

An associate's degree with 5 years of experience, or 10 or more years of injection molding experience.
Hands-on experience setting up molding machines, hot runners, and auxiliary equipment such as dryers, TCUs, and robotics.
Experience with DOE, Cpk/Ppk, and SPC.
Ability to read prints and GD&T and interpret dimensional reports.
Experience supporting APQP, PFMEA, control plans, and PPAP.
Ability to communicate effectively with Launch Engineering, Tooling, Metrology, Quality, and Production.
Systematic troubleshooting and problem-solving skills.
Ability to work independently and meet tight launch timelines.
Understanding of Lean concepts, including standardized work, problem solving, and setup and scrap reduction.
Regular and consistent attendance.

Nice To Haves

Process Engineering degree.
RJG Master Molder certification or equivalent scientific molding training.
Experience with Minitab or similar statistical software.

Responsibilities

Own sampling and process development for new molds, from DOE planning and first shots through the validation run.
Develop, optimize, and document robust molding and packaging processes, including stable process settings, machine setups, and mold documentation.
Support launch feasibility and mold-flow reviews, prepare DOE plans, and ensure the press, material, and auxiliary equipment are ready.
Prepare arriving molds and run the RMT; execute DOE runs and analyze results to establish the process window.
Own molding-process parameters, cavity-to-cavity and run-to-run consistency, and machine and peripheral equipment during launch.
Run confirmation samples, request temporary master approval, and support capability, run-at-rate, and PPAP activities.
Lead packaging tests, set up the workstation with Production, and confirm the final pack quantity in X2.
Collaborate with the Manufacturing Engineer on complete cell setup.
Troubleshoot mold, process, dimensional, and cosmetic issues at the press with the Launch Engineer, Tooling, Metrology, and Quality; identify root causes and distinguish process issues from tool issues.
Run follow-up samples after tool adjustments, including the 165-piece split, to verify corrections, and report results to the Launch Engineer for APQP tracking.
Save the stable process, complete machine, robot, and HAL setups, build the mold documentation book, and support the PFMEA and control plan.
Confirm cycle time against the quote and hand off proven processes to production Process Engineers.
Mentor and develop others.