Sr. Mold Engineer II - Molding & Tooling

Alcon USA•Houston, TX

1d•Onsite

About The Position

The Sr. Mold Engineer II, Molding & Tooling, assists with mold tooling development by analyzing injection molding parameters and optimizing processes. The role supports defect troubleshooting, quality control, and process efficiency improvements, and collaborates with engineers to refine mold designs and improve manufacturability at Alcon’s manufacturing facility in Houston, Texas. The position leads molding engineering and validation activities for new product introductions, remediation efforts, and sustaining manufacturing programs. As a technical subject matter expert in thermoplastic and liquid silicone rubber (LSR) injection molding, the engineer uses data-based analysis to optimize processes, troubleshoot issues, and implement robust manufacturing controls. The role owns quality-system deliverables across platforms including Kneat, Teamcenter, NCI investigations, CAPAs, Change Controls, and validation documentation. The engineer develops and executes validation strategies and roadmaps, including IQ, OQ, PQ, TMV, and process validation activities. Responsibilities include leading defect investigations and root cause analysis, implementing corrective and preventive actions, and improving cycle time, yield, scrap, OEE, and manufacturing efficiency. The role partners with Tooling, Product Development, Quality, Manufacturing, and external suppliers to improve mold designs, processing windows, and product manufacturability throughout the product lifecycle. The position leads project planning and execution, mentors engineers and technicians, and authors, reviews, approves, and maintains technical and quality documentation. It also leads controlled-document creation and approval in Veeva QualityDocs, represents Molding Engineering during audits and inspections, and ensures compliance with GxP, regulatory requirements, data integrity expectations, training requirements, and quality-system policies. The role is onsite in Houston, Texas, Monday through Friday, 7:00 AM–4:00 PM CST, with travel of up to 10%. No relocation assistance or sponsorship is available.

Requirements

Bachelor’s degree or equivalent directly related experience; stated equivalencies include high school plus 10 years, an associate degree plus 6 years, or an M.S. with 0 years.
Fluent ability to read, write, understand, and communicate in English.
2 years of relevant experience.
1 year of demonstrated leadership.
Ability to work onsite in Houston, Texas, Monday through Friday, 7:00 AM–4:00 PM CST.
Ability to travel up to 10%.

Nice To Haves

Liquid Silicone Rubber (LSR) experience.
Project management experience.
Molding process development and troubleshooting experience.

Responsibilities

Lead molding engineering and validation activities for new product introductions, remediation efforts, and sustaining manufacturing programs.
Serve as a technical subject matter expert for thermoplastic and LSR injection molding processes, using data-based analysis to optimize processes, troubleshoot issues, and implement manufacturing controls.
Own quality-system deliverables across Kneat, Teamcenter, NCI investigations, CAPAs, Change Controls, and validation documentation.
Develop, govern, and execute validation strategies and roadmaps, including IQ, OQ, PQ, TMV, and process validation activities.
Lead complex defect investigations and root cause analysis, and implement sustainable corrective and preventive actions.
Optimize cycle time, yield, scrap, OEE, and overall manufacturing efficiency.
Partner with Tooling, Product Development, Quality, Manufacturing, and external suppliers to optimize mold designs, processing windows, and product manufacturability.
Lead continuous improvement initiatives using Lean Manufacturing, Six Sigma, and data-driven methods.
Plan and execute projects by developing plans, tracking deliverables, managing risks, escalating issues, and achieving milestones.
Coach and mentor engineers, technicians, and cross-functional team members; promote technical excellence and knowledge sharing.
Author, review, approve, and maintain technical and quality documentation in accordance with internal procedures, regulations, and quality-system requirements.
Lead the creation, revision, and approval of controlled documents in Veeva QualityDocs, including procedures, work instructions, validation protocols, reports, and Documentation Change Controls.
Represent Molding Engineering during audits, inspections, management reviews, and cross-functional governance meetings.
Ensure compliance with GxP requirements, approved procedures, documentation and data-integrity expectations, training requirements, and quality-system policies.
Maintain accountability for individual performance, project execution, and organizational compliance while supporting a culture of safety, quality, continuous improvement, and operational excellence.