Impact-Driven Injection Molding Process Engineer

Aegis Worldwide; Anderson (IN); On-site; USD 85,000 - 125,000; Full time

Job summary

Aegis Worldwide is seeking a Process Engineer to establish and optimize injection molding processes, delivering safe, repeatable, and cost-effective production. You will own process definition, control, troubleshooting, and continuous improvement across molding operations.

The role partners with Operations, Maintenance, Tool Room, and Quality to eliminate scrap and downtime, trains staff on standard work, and uses DOE and SPC to drive permanent solutions.

Qualifications

• Bachelor's degree in Engineering (Plastics, Mechanical, Manufacturing, or related).
• 7–10 years of hands-on injection molding process engineering experience.
• Strong understanding of PP and PC material behavior in molding applications.
• Proven ability to analyze data and solve complex process problems.

Responsibilities

• Establish scientifically validated process windows for PP, PC, and similar resins.
• Define and maintain golden settings based on melt temperature, shear, injection velocity, pack/hold, cooling, and mold temperature control.
• Own process setup sheets, standard work, and controlled parameter limits.
• Train and mentor the organization to run and protect molding processes correctly.
• Lead engineering analysis of defects such as flow hesitation, jetting, sinks, warp, blush, splay, burns, voids, and dimensional instability.
• Correlate defects to material condition, mold design, and machine dynamics.
• Use DOE, cavity pressure trends, and SPC data to drive permanent solutions.
• Support mold trials, steel-safe changes, and new tool introductions.
• Ensure molds are technically capable of running defined process windows.
• Provide engineering input on wear components and mold PM requirements.
• Own molding-related process capability (Cp/Cpk).
• Implement SPC on critical process parameters and part characteristics.
• Transition quality control from inspection-based to process-controlled.
• Support investigations into scrap, quality holds, and customer complaints with data-driven analysis.
• Support commissioning and validation of equipment and downstream automation.

Skills

Analytical skills

Problem solving

Communication

Teamwork

Lean manufacturing

Continuous improvement

SPC experience

Education

Bachelor’s degree in Engineering (Plastics, Mechanical, Manufacturing, or related)

RJG Master Molder I or II or equivalent certification

DOE, Six Sigma exposure

Tools

RJG Master Molder I/II

Statistical Process Control (SPC)

Design of Experiments (DOE)

Six Sigma

Job description

Aegis Worldwide is seeking a Process Engineer to establish and optimize injection molding processes, delivering safe, repeatable, and cost-effective production. You will own process definition, control, troubleshooting, and continuous improvement across molding operations.

The role partners with Operations, Maintenance, Tool Room, and Quality to eliminate scrap and downtime, trains staff on standard work, and uses DOE and SPC to drive permanent solutions.