Global R&D Healthcare Product Development Engineer

Amcor • Lancaster, PA

15d • Onsite

About The Position

As a member of the Product Development team, the Product Development Engineer is a hands-on technical specialist responsible for executing the engineering and development activities that bring new healthcare packaging products to life. Working under the direction of the Product Development Manager, the Engineer carries out plant trials, process development, design verification, and testing activities with a high degree of personal ownership and technical depth. This role is critical to translating project requirements into qualified, manufacturable products — and serves as the primary technical executor within the Stage-Gate development process. This position collaborates closely with Operations, Quality, Toolmakers, Suppliers, and Customers to deliver products that meet specifications, schedule, and cost targets.

Requirements

• Bachelor’s degree in Engineering, Polymer Science, or equivalent experience.
• 2–5 years of hands-on experience with injection molded plastic closures and/or blow molded plastic bottles, including direct operation and setup of production equipment.
• Demonstrated ability to personally execute DOE, process validations, and line trials.
• Ability to travel as needed (20–40%), including on-site customer and supplier visits.
• Good verbal and written communication skills; able to document technical work clearly and accurately.
• Working knowledge of statistical methods and programs (SPC/DOE/MiniTab).
• Self-motivated individual with a hands-on, problem-solving mindset.
• Able to manage multiple tasks in a fast-paced development environment.
• Strong attention to detail and commitment to data-driven decision making.

Nice To Haves

• Healthcare or regulated-industry packaging background preferred.

Responsibilities

• Execute plant trials, line qualifications, and process validations hands-on, including setting up tooling, equipment, and fixtures directly on the production floor.
• Run Design of Experiments (DOE) and process capability studies at the machine level, collecting and analyzing data in real time to optimize process parameters.
• Set up and operate injection molding, blow molding, and related equipment during development trials; adjust process parameters to improve part quality and cycle time.
• Build and verify first-article samples, perform dimensional checks using CMM and hand gauges, and document results to specification.
• Troubleshoot tooling, mold, and processing issues during trials, working directly with die/tool shops and toolmakers to drive timely resolution.
• Develop and execute sample and test plans, procure test fixtures and gages, and carry out or coordinate metrology verification activities.
• Support customer line trials on-site at customer facilities, acting as the technical representative during qualification runs.
• Participate in and contribute to DFMEA/PFMEA workshops, applying hands-on trial experience to identify failure modes and propose mitigations.
• Execute assigned tasks within the Stage-Gate process, meeting milestone deliverables on time, to specification, and within budget.
• Support the Product Development Manager in preparing technical documentation including test plans, costing inputs, design requirement records, and qualification reports.
• Assist in developing project scope, design requirements, DFMEA, sample plans, and risk assessments under the guidance of the PM.
• Maintain accurate and up-to-date project records, trial logs, and test data; contribute inputs to the Technical Development Plan.
• Track and report on individual task progress; flag risks or deviations to the PM promptly to enable timely corrective action.
• Support the controlled transition of qualified products to Operations, ensuring all documentation and specifications are complete and accurate.
• Adhere to Berry/Amcor, industry, and regulatory procedures including Management of Change, Stage Gate, and ISO processes.
• Support the product design process: contribute to ideation sessions, competitive analysis, design requirement documentation, and design reviews alongside the PM and Design Engineers.
• Apply analytical tools (FEA, MoldFlow, etc.) under guidance to evaluate functionality and moldability, helping to minimize steel iterations and reduce cost.
• Contribute to technology evaluation activities, providing hands-on data and trial observations to inform technology selection.
• Support preparation of customer and stakeholder design review materials; contribute technical content for presentations and gate reviews.
• Serve as a technical resource for Manufacturing and Quality on product-related queries during development and early production.

Benefits

• Medical, dental and vision plans
• Flexible time off, starting at 80 hours paid time per year for full-time salaried employees
• Company-paid holidays starting at 8 days per year and may vary by location
• Wellbeing program & Employee Assistance Program
• Health Savings Account/Flexible Spending Account
• Life insurance, AD&D, short-term & long-term disability, and voluntary benefits
• Paid Parental Leave
• Retirement Savings Plan with company match
• Tuition Reimbursement (dependent upon approval)
• Discretionary annual bonus program (initial eligibility dependent upon hire date)

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level