Senior Manufacturing Engineer

Marmon Holdings, Inc.•Charlottesville, VA

2d•Onsite

About The Position

The Senior Manufacturing Engineer provides technical leadership for manufacturing operations supporting both existing products and new product introductions, with a strong emphasis on plastic injection molding processes, tooling, automation, and process optimization. This role is responsible for developing, validating, optimizing, and sustaining molding processes and manufacturing systems that improve product quality, scalability, and operational performance. You’ll collaborate cross-functionally, solve complex challenges, and help shape future manufacturing capabilities through innovation, scientific molding, and continuous improvement.

Requirements

Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Plastics Engineering, or related field
5+ years of manufacturing engineering experience, ideally supporting injection molding or high-volume production environments
Hands-on experience with injection molding process development, scientific molding, tooling validation, and troubleshooting
Deep understanding of injection molding processes, tooling design, and process optimization
Strong troubleshooting capability across molding defects, cycle optimization, and process stability
Experience with validation (IQ/OQ/PQ), DOE, SPC, and statistical analysis
Knowledge of GD&T, tolerance analysis, and plastic part design considerations
Familiarity with Lean manufacturing and continuous improvement methodologies
Strong analytical and data-driven problem-solving skills
Ability to lead complex projects and influence cross-functional teams
Excellent documentation and process standardization practices
Effective communicator with the ability to work across all levels of the organization
Passion for innovation, continuous improvement, and technical excellence

Nice To Haves

Experience with automation, robotics, vision systems, or advanced manufacturing technologies
Knowledge of engineered thermoplastics, resin behavior, and mold flow principles

Responsibilities

Lead Design for Manufacturing (DFM) and Design for Assembly (DFA) efforts focused on injection molded components, improving manufacturability, quality, and cost
Develop, validate, and optimize injection molding processes, tooling, fixtures, automation systems, and secondary operations
Establish and refine molding parameters (fill, pack, hold, cooling, resin drying, cycle time) using scientific molding principles
Support mold design reviews, tooling qualification, first article inspection, and production readiness
Troubleshoot molding defects such as flash, sink, short shots, warp, splay, burns, and dimensional variation
Partner with tooling vendors, resin suppliers, and automation integrators to improve mold performance and uptime
Evaluate and implement advanced manufacturing technologies including robotics, vision systems, and smart manufacturing solutions
Lead new product introduction (NPI), process validation (IQ/OQ/PQ), DOE studies, and production launch readiness
Develop scalable manufacturing strategies that support growth, efficiency, and long-term performance
Author and maintain key documentation including PFMEA, control plans, work instructions, and process flows
Lead engineering changes including tolerance analysis, resin evaluation, and mold/process improvements
Serve as technical lead for complex manufacturing and quality challenges, driving root cause analysis and corrective actions
Drive continuous improvement using Lean, Six Sigma, Kaizen, and scientific molding methodologies
Mentor Manufacturing Engineers and Process Technicians, supporting technical growth and capability development
Partner cross-functionally with Engineering, Operations, Quality, Supply Chain, and external stakeholders to achieve business objectives