Lead Molding & Tooling Engineer - NPI & Process Excellence

Alcon; Hurricane (WV); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Health benefits

Retirement plan

Paid time off

Relocation assistance

Job summary

Alcon is seeking a Principal, Molding & Tooling Engineering to lead strategic and technical initiatives in injection molding, mold/tooling design, and manufacturing optimization. You will serve as SME for molding, drive innovations, support NPI, and ensure quality and cost targets across global operations from R&D transfer through production ramp-up.

You will mentor engineers, oversee tooling validations, coordinate cross-functional activities, and collaborate with suppliers to deliver robust

Qualifications

• Bachelor's degree or equivalent in Engineering or related field.
• Fluent reading/writing/understanding English.
• 5 years of relevant experience.
• Work Hours: Exempt 40 hours/week, Mon-Fri, 8:00 AM–5:00 PM EST.
• Travel up to 10%.
• Location: Onsite.
• Relocation is available.
• Sponsorship is not available.

Responsibilities

• Design and develop precision mold tooling and optimize injection molding processes for efficiency, reliability, and part quality.
• Lead and approve improvements and validations for injection molds, tooling support systems, and molding equipment.
• Provide technical guidance during mold maintenance, qualification, and machine/equipment troubleshooting.
• Investigate process issues and implement advanced improvements in tooling design and manufacturing techniques.
• Define and optimize molding processes through capability studies, DOE, root cause analysis, and validation activities (IQ/OQ/PQ).
• Oversee molding trials, process documentation, and assess raw material impacts on molding performance.
• Collaborate with cross-functional partners to reduce defects, enhance mold performance, and elevate production throughput.
• Scout and evaluate advanced tooling technologies and auxiliary equipment to drive safety, efficiency, and cost savings.
• Recommend capital investments, support tooling standardization, and write capital justifications.
• Support New Product Introduction (NPI) from concept through production ramp-up, managing timelines, risks, and cost targets.
• Partner with suppliers, contract manufacturers, and global teams to ensure robust solutions across the product lifecycle.
• Mentor junior engineers and technicians on best practices in molding, tooling, and process development.
• Ensure all tooling designs and molding processes meet regulatory, safety, and quality requirements for medical devices.
• Maintain documentation, change control, and quality compliance across internal and external systems.
• Uphold GxP requirements by following SOPs, maintaining accurate documentation, and ensuring rigorous quality control.
• Contribute to a culture of continuous improvement and operational excellence

Skills

Injection molding

Mold tooling

Process improvement

DOE

Problem solving

Education

Engineering degree

Tools

Hot runner systems

Automation tooling

Process monitoring systems

Dimensional inspection tools

Job description

Alcon is seeking a Principal, Molding & Tooling Engineering to lead strategic and technical initiatives in injection molding, mold/tooling design, and manufacturing optimization. You will serve as SME for molding, drive innovations, support NPI, and ensure quality and cost targets across global operations from R&D transfer through production ramp-up.

You will mentor engineers, oversee tooling validations, coordinate cross-functional activities, and collaborate with suppliers to deliver robust