Engineering Technician: Injection Molding
1025 LEGO Manufacturing Virginia Inc.
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Benefits offered by this job
Job summary
The LEGO Group is seeking a seasoned injection molding expert in Virginia to lead advanced diagnostics, problem solving, and process optimization for high-volume production. You will diagnose across process, machine, mold, and controls, coordinating with Engineering, Maintenance, Automation, and Quality teams.
You will apply scientific molding principles, run structured studies, and use DOE and capability analysis to deliver repeatable, robust processing windows while ensuring safety and product
Qualifications
- Minimum 5 years of progressively advanced technical experience in injection molding in high-volume manufacturing.
- Advanced expertise in scientific molding, process development, and complex diagnostics.
- Experience leading root-cause investigations and cross-functional project teams.
Responsibilities
- Diagnose complex injection molding problems across process, machine, mold, material, and controls.
- Lead root-cause investigations and coordinate cross-functional teams.
- Verify effectiveness of corrective actions through process capability and production results.
Skills
Education
Tools
Job description
- Advanced Injection Molding Diagnostics & Technical Problem Solving Serve as a primary technical escalation point for complex, chronic, or high-impact injection molding problems beyond standard production troubleshooting and routine process adjustments.
- Independently diagnose manufacturing problems across Process, Machine, Mold, Material, Controls, Automation, auxiliary equipment, and operating practices, including interactions between these systems.
- Analyze molding parameters, machine and process data, alarm histories, equipment behavior, production trends, and product defects to isolate technical failure modes and sources of manufacturing variation.
- Lead structured root cause investigations, develop evidence-based conclusions and corrective-action recommendations, and coordinate Engineering, Maintenance, Automation, Quality, and other specialized resources when required.
- Verify corrective-action effectiveness through process capability, quality, equipment, and sustained production results, emphasizing elimination of systemic causes rather than repeated correction of symptoms.
- Apply advanced scientific molding principles to troubleshoot, develop, evaluate, and optimize injection molding processes and establish robust, repeatable processing windows.
- Execute and interpret advanced molding studies including fill, pressure-loss, gate-seal, viscosity, cooling, process-window, capability, and other structured technical studies.
- Analyze relationships between machine settings, actual process conditions, material behavior, mold performance, environmental conditions, automation, and finished-product quality.
- Apply statistical methods, process capability analysis, structured trials, and Design of Experiments (DOE), where applicable, to identify significant variables and develop technically supported recommendations.
- Optimize molding processes to improve cycle time, scrap, uptime, productivity, capability, and OEE while maintaining established safety, quality, and process-control requirements.
- Utilize molding-machine controls, HMI diagnostics, alarm histories, process-monitoring systems, and manufacturing data to diagnose complex process and equipment abnormalities.
- Diagnose interactions among molding machines, molds, hot runner systems, auxiliary equipment, material‑handling systems, automation, robotics, and downstream processes.
- Analyze PLC/HMI diagnostic information, sensors, I/O status, alarms, interlocks, machine sequences, and equipment feedback to distinguish process issues from controls, automation, electrical, or mechanical problems.
- Read and interpret technical drawings, mold documentation, control diagrams, electrical schematics, process specifications, and equipment documentation required for advanced diagnostics.
- Provide Engineering, Machine Maintenance, Mold Maintenance, and Automation teams with technical evidence and execute process verification and stabilization following repairs, modifications, controls changes, or significant maintenance events.
- Execute technical qualification and validation activities for injection molds, molding processes, equipment, materials, and associated manufacturing systems through structured studies, trials, data analysis, and capability evaluations.
- Evaluate mold and process performance following repairs, engineering modifications, transfers, equipment changes, and new production launches, identifying risks to stable and capable manufacturing.
- Execute technical test plans and validation protocols, analyze results against established acceptance criteria, and document findings, manufacturing risks, process capability, and recommendations.
- Support equipment commissioning, installation, startup, production acceptance, and manufacturing readiness, including participation in FAT/SAT activities where applicable.
- Evaluate and verify process capability and stability during production ramp-up and new product introduction using objective manufacturing data to confirm repeatable operation within approved processing windows and quality requirements.
- Analyze real-time and historical process, equipment, quality, cycle-time, downtime, scrap, capability, and OEE data to identify abnormal conditions, recurring failure modes, and technical relationships not evident through routine troubleshooting.
- Translate complex manufacturing information into documented technical findings, recommendations, corrective actions, and data-driven diagnostic or monitoring methods that support process optimization and prevention of manufacturing losses.
- Serve as an advanced injection molding technical resource for Process Technicians, Setters, Operators, Maintenance Technicians, Production Teams, and cross-functional technical partners.
- Provide technical direction and coaching in scientific molding, structured troubleshooting, process controls, root cause analysis, manufacturing data interpretation, and disciplined technical problem solving.
- Develop and improve troubleshooting standards, diagnostic methodologies, technical documentation, process-control practices, and injection molding best practices while supporting knowledge transfer and continuous improvement across local and global molding organizations.
- Minimum 5 years of progressively advanced technical experience in injection molding within a high-volume manufacturing environment, including responsibilities beyond routine machine setup, process adjustment, and standard production troubleshooting.
- Demonstrated advanced expertise in scientific molding, injection molding process development, complex diagnostics, process optimization, and establishment or evaluation of robust processing windows.
- Demonstrated experience independently executing advanced molding studies, technical trials, structured root cause investigations, process capability evaluations, and qualification or validation activities.
- Advanced understanding of interactions among molding machines, molds, materials, hot runner systems, process parameters, auxiliary equipment, controls, automation, and product quality, including the ability to diagnose multi-system manufacturing problems.
- Experience supporting mold qualifications, process validations, equipment commissioning/startups, production launches, manufacturing‑readiness activities, and technical corrective actions while independently organizing complex technical investigations and engaging cross-functional resources.
- Associate degree, technical diploma, apprenticeship, military technical training, recognized technical certification, or equivalent combination of technical education, training, and directly relevant advanced injection molding experience.
- Technical education or training in plastics technology, injection molding, manufacturing engineering technology, mechatronics, industrial technology, automation, controls, tooling, or a related technical discipline is preferred.
- Advanced Scientific Molding, RJG, AIM, Paulson, or equivalent injection molding training or certification is preferred.
- Technical training in industrial controls, automation, mechatronics, PLC‑controlled equipment, robotics, or industrial electronics is preferred.
- A bachelor's degree in Engineering is not required.
- Advanced technical knowledge of injection molding processes, scientific molding principles, process capability, process variation, and manufacturing stability.
- Advanced analytical and diagnostic capability with the ability to independently investigate complex interactions among Process, Machine, Mold, Material, Controls, Automation, and operational factors.
- Ability to execute and interpret advanced molding studies, technical trials, capability evaluations, qualification and validation activities, and manufacturing data analysis.
- Working technical knowledge of molding‑machine controls and automated manufacturing systems, including PLC/HMI diagnostics, sensors, I/O, alarms, interlocks, machine sequencing, and applicable technical drawings and documentation.
- Strong technical leadership, communication, documentation, and coaching capability with the ability to translate complex technical findings into actionable recommendations and work effectively across Operations, Engineering, Maintenance, Automation, and Quality.
The salary for this position has a range of $36.85 - $36.85 based on anticipated responsibilities, market benchmarks, and organizational constraints. The LEGO Group carefully considers a wide range of compensation factors, including but not limited to prior experience, skills, expertise, location, internal equity, and other considerations permitted by law. The comprehensive remuneration details, inclusive of benefits, will be communicated upon finalisation of the employment offer.
- Family Care Leave – We offer enhanced paid leave options for those important times.
- Insurances – All colleagues are covered by our life and disability insurance which provides protection and peace of mind.
- Wellbeing – We want you to be your best self, so you’ll have access to the Headspace App and lots of wellbeing initiatives and programs run by local teams where you are based
- Colleague Discount – We know you'll love to build so from day 1 you will qualify for our generous colleague discount.
- Bonus – We do our best work to succeed together. When goals are reached and if eligible, you'll be rewarded through our bonus scheme
Your workplace will be the office, store or factory specified in this advert.
Our hybrid work model, Best of Both offers you the option of flexibility to work from home up to two days per week. Your People Leader will discuss the principles of the model, including how this option applies to your role and team. Learn more about our benefits, culture and workplace experience here
We strive to create a diverse, dynamic and inclusive culture of play at the LEGO Group, where everyone feels safe, valued and they belong. The LEGO Group is highly committed to equal employment opportunity and equal pay and seeks to encourage applicants from all backgrounds (eg. sex, gender identity or expression, race/ethnicity, national origin, sexual orientation, disability, age, religion and Veteran status) to apply for roles in our team.
The LEGO Group is fully committed to Children’s Rights and Child Wellbeing across the globe. Candidates offered positions with high engagement with children are required to take part in Child Safeguarding Background Screening, as a condition of the offer. Thank you for sharing our global commitment to Children’s Rights. We conduct drug screening as a part of our drug free workplace policy and in support of our commitment to the health and safety of our employees.
Online Application Accessibility Statement; which is intended for people with disabilities - LEGO systems endeavors to make www.LEGO.com/jobs accessible to any and all users.
If you would like to contact us regarding the accessibility of our web site or need assistance completing the application process, please contact the HR Service Desk at 1.860-763-7777, option #3. Please note, these communication channels should be used for those having difficulty accessing our on-line channels, not to inquire about job opportunities.
Our founder Ole Kirk Kristiansen made his first wooden toy in 1932. He persevered against the odds until his business was a success. Constantly innovating, never compromising. Building, rebuilding, and striving for the best. It is this resilience and permanent sense of renewal that drives us forward. We are never still. We will always be creating, inventing, and having fun. Build your career brick by brick and play your part in continuing our mission to "inspire and develop the builders of tomorrow".
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