Molding Process Engineer

FIFO International; Ernakulam; On-site; INR 900,000 - 1,500,000; Full time

Job summary

FIFO International is seeking a Process Engineer to develop and optimize injection moulding processes, support NPI, and drive continuous improvement across production lines.

The role includes process validation, troubleshooting, and maintaining documentation to ensure quality and efficiency in a manufacturing setting.

Qualifications

• Develop and optimize injection moulding processes for new and existing products.
• Validate processes and establish standard parameters to ensure stable production.
• Provide technical support to production, troubleshoot defects, and drive continuous improvement.

Responsibilities

• Develop, establish, and optimize injection moulding processes for new and existing products.
• Perform process setup, parameter optimization, and validation to achieve stable production.
• Support new mould trials, first-off approvals, and production readiness.
• Participate in NPI activities from RFQ through mass production.
• Conduct process capability studies and establish standard process parameters.
• Provide technical support to production teams for process-related issues.
• Troubleshoot moulding defects and implement corrective actions.
• Improve cycle time, productivity, and OEE; minimize scrap and FPY loss.
• Prepare and maintain process documentation (PFMEA, PFD, Control Plan, SOPs).
• Lead Kaizen, Lean, and Six Sigma initiatives to reduce costs.
• Ensure compliance with quality standards and support audits.

Skills

Injection Moulding

Lean Manufacturing

Kaizen

OEE Improvement

Root Cause Analysis

Process Validation

NPI

Automation

Education

B.E./B.Tech in Mechanical/Polymer/Production/Plastics

Tools

AutoCAD

Creo

SAP

QAD

Oracle

Job description

JOB TITLE

Process Engineer / Senior Process Engineer – Moulding

DEPARTMENT

MOULDING

Job Summary

Responsible for developing, optimizing, and sustaining injection moulding processes to achieve production targets for quality, productivity, cost, and delivery. The role supports New Product Introduction (NPI), process validation, troubleshooting, continuous improvement, and customer requirements while ensuring compliance with quality and safety standards.

Key Responsibilities

Process Engineering

• Develop, establish, and optimize injection moulding processes for new and existing products.
• Perform process setup, parameter optimization, and validation to achieve stable production.
• Support new mould trials, first-off approvals, and production readiness.
• Participate in new product introduction (NPI) activities from RFQ through mass production.
• Conduct process capability studies and establish standard process parameters.

Production Support

• Provide technical support to production teams for process-related issues.
• Troubleshoot moulding defects and implement effective corrective actions.
• Improve cycle time, productivity, machine utilization, and Overall Equipment Effectiveness (OEE).
• Minimize process scrap and improve First Pass Yield (FPY).

Process Documentation

• Prepare and maintain process documentation, including:
• PFMEA
• Process Flow Diagram (PFD)
• Control Plan
• Standard Operating Procedures (SOPs)
• Process Validation Reports
• Trial Reports
• Work Instructions

Continuous Improvement

• Lead Kaizen, Lean Manufacturing, and Six Sigma initiatives.
• Drive cost reduction through process optimization and waste elimination.
• Implement poka-yoke and process improvements to enhance product quality and efficiency.
• Analyze production data and identify opportunities for improvement.

Quality & Customer Support

• Ensure compliance with customer specifications and quality standards.
• Support customer audits, process audits, and product qualification activities.
• Participate in root cause analysis using 8D, 5 Why, Fishbone, and FMEA methodologies.
• Support PPAP, APQP, and engineering change implementation.

Cross-Functional Coordination

• Coordinate with Tool Room, Quality, Maintenance, Production, Planning, and NPI teams.
• Support mould modifications and engineering changes.
• Conduct operator and technician training on process standards and best practices.

Safety & Compliance

• Ensure adherence to EHS policies and safe moulding practices.
• Maintain compliance with ISO 9001, IATF 16949, ISO 14001, and company standards.
• Promote 5S and workplace safety initiatives.

Key Skills & Competencies

• Injection Moulding Process Optimization
• Scientific Moulding Techniques
• Process Validation & Qualification
• NPI & Production Support
• PFMEA, Control Plan & PPAP
• Root Cause Analysis (8D, 5 Why)
• OEE & Productivity Improvement
• Lean Manufacturing & Kaizen
• AutoCAD / Creo
• ERP Systems (SAP/QAD/Oracle)
• MS Office
• Strong Analytical & Problem-Solving Skills
• Good Communication & Team Collaboration

Qualifications

• B.E./B.Tech in Mechanical, Polymer, Production, or Plastics Engineering.

Experience

Senior Process Engineer

• 5–8 years of experience in Injection Moulding Process Engineering in a manufacturing environment.