Injection Molding Process Optimization Engineer

Torrey Holistics; Anderson (IN); On-site; USD 90,000 - 120,000; Full time

Job summary

Torrey Holistics in Anderson, IN seeks an Injection Molding Process Optimization Engineer to own, stabilize, and sustain robust molding processes. You will create and safeguard scientifically grounded process windows for PP/PC resins, setting golden settings via melt and pressure controls, and mentor teams to protect process performance.

This hands-on role uses DOE, cavity pressure monitoring, and SPC to drive lasting fixes, collaborating with Tool Room, Maintenance, Quality, and Operations to

Qualifications

• Bachelor’s degree in engineering (plastics, mechanical, manufacturing, or related field).
• 7–10 years of hands-on injection molding process engineering experience.
• Strong data analysis and problem solving of complex process issues.
• Knowledge of PP and PC behavior in molding applications.

Responsibilities

• Own the definition, stabilization, and sustainment of robust injection molding processes.
• Develop and validate scientific process windows for resins; set golden settings.
• Lead mold trials; drive root-cause corrective actions using DOE and SPC.
• Collaborate with Tool Room, Maintenance, and Quality to reduce scrap and downtime.
• Implement process control; shift quality checks toward process validation.

Skills

Process optimization

DOE

SPC

Root cause analysis

Data analysis

Troubleshooting

Lean manufacturing

Six Sigma

Education

Bachelor’s degree in Engineering

Tools

MS Office

MES

Job description

A day in the lifeYou start your morning on the production floor, walking press to press, confirming that golden settings are locked in and that cavity pressure trends look healthy. A robot cycle is a beat slow on one tool; you adjust pack/hold and cooling balance to protect part performance without sacrificing mold life. Later, you partner with Maintenance to restore peak cooling circuit flow on a high-cavitation PP mold, then brief Quality and Operations on a plan to shift from inspection-heavy checks to process-driven control. By the end of the day, scrap tied to splay and blush is down, cycle time is optimized, and the organization is trained to run the window you established.Role detailsPosition Title: Injection Molding Process Optimization EngineerReports To: Sr. Manager of EngineeringOffice Location: AndersonDepartment: Engineering / OperationsNote: The following overview outlines the general nature and scope of the work. It does not represent an exhaustive inventory of all duties, responsibilities, or skills.PurposeOwn the definition, stabilization, and sustainment of robust, safe, and cost-effective injection molding processes. You will create and safeguard scientifically grounded process windows, eliminate variability and downtime, and lead continuous improvement across electric, hydraulic, and hybrid presses, robots, and downstream systems.This is a hands-on, floor-centered position that underpins plant stability and performance.What you will ownDevelop and validate scientific process windows for PP, PC, and related resins.Set and maintain golden settings using melt temperature and shear, injection velocity profiles, pack/hold pressure and time, cooling efficiency, and mold temperature control.Incorporate resin behavior into process design: viscosity, shrinkage, and crystallization for PP; thermal sensitivity for PC.Create and control setup sheets, standard work, and parameter limits; mentor teams to run and protect processes.Diagnose complex defects (flow hesitation, jetting, sinks, warp, blush, splay, burns, voids, dimensional drift) and drive permanent resolution.Link symptoms to root causes in material condition (moisture, degradation), mold design (venting, cooling, gating), and machine dynamics (pressure response, screw recovery).Use DOE, cavity pressure monitoring, and SPC to identify and implement lasting fixes.Collaborate with Tool Room and Maintenance to enhance cooling circuits, venting and gas evacuation, and ejection/part release.Lead mold trials, support steel-safe changes, and introduce new tools; verify technical capability to run within defined windows.Specify wear components and mold PM needs; ensure process capability (Cp/Cpk) targets are owned and achieved.Implement SPC on critical process parameters and part characteristics; move quality control from inspection to process control.Investigate scrap, quality holds, and customer complaints using data-driven methods.Commission and validate presses, robots, dryers, chillers, and material handling systems; confirm machine capability versus resin and mold requirements.Optimize cycle times without compromising part integrity or mold longevity.Champion adherence to safety, environmental, and quality procedures.Coordinate across shifts and maintain clear communication to ensure process consistency.Perform other related duties as assigned.Education and experienceRequiredBachelor’s degree in Engineering (Plastics, Mechanical, Manufacturing, or related field).7–10 years of hands-on injection molding process engineering experience.Demonstrated knowledge of PP and PC behavior in molding applications.Track record of data analysis and solving complex process issues.PreferredRJG Master Molder I or II (or equivalent scientific molding certification).Exposure to DOE, SPC, and Six Sigma methodologies.Background in high-volume, multi-press environments.Knowledge, skills, and abilitiesDeep command of injection molding science, mold design fundamentals, resin behavior, and process parameters.Ability to interpret engineering drawings, specifications, and process data.Strong analytical, troubleshooting, and root-cause capabilities.Experience with SPC, structured problem solving, and quality improvement tools.Clear communicator and collaborative team player.Self-starter with demonstrated initiative for process improvement.Familiarity with Lean and continuous improvement practices.Proficient with MS Office and manufacturing execution systems (MES).Technical proficienciesBachelor’s Degree / Engineering DegreeData analysis and manipulation; Quality control data analysisContinuous improvement, Kaizen, Lean manufacturing principlesMeasurement System Analysis (MSA)Root cause methods: 5 Why, Fishbone (Ishikawa)Advanced Product Quality Planning (APQP)Supplier managementMotor replacement, repair, and maintenanceManufacturing Instructions (MI) creation and adherenceTroubleshooting industrial automation equipmentProcess engineering; Process developmentProduction optimizationDesign for Manufacturability (DFM) and Design for Assembly (DFA)Quality control experience; Non-conforming product identificationMechanical design and engineering; Tolerance analysisElectrical / electronic systems familiaritySix Sigma experienceOperational risk managementProduction planning and schedulingHigh-level operations analysisBudgeting and forecasting exposure