Plastic Process Engineering Manager

PlasticStaffing.com; Wisconsin; On-site; USD 90,000 - 140,000; Full time

Job summary

PlasticStaffing.com is seeking an experienced Process Engineering Manager in Wisconsin to lead injection molding process development and optimization. You will guide a skilled team, drive DOE/SPC/capability studies, and ensure robust, production-ready processes for high-precision plastic and elastomeric components.

Cross-functional collaboration and continuous improvement are essential. The role emphasizes leadership, technical excellence, and a focus on safety, quality, and efficiency in a

Qualifications

• 5+ years of hands-on injection molding process engineering in manufacturing.
• Experience developing, optimizing, troubleshooting, and validating injection molding processes using scientific molding principles.
• Proven leadership of engineering personnel, projects, or technical teams.
• Experience with IQ/OQ/PQ, DOE, SPC, capability studies, and root-cause analysis.
• Experience with engineered polymers and/or LSR processes.
• Strong project management and cross-functional collaboration skills.

Responsibilities

• Lead, supervise, mentor, and develop the Process Engineering team.
• Establish SQDC-focused culture and drive process development for high-precision components.
• Develop and maintain robust injection molding processes with science-based windows and standards.
• Lead process development and qualification supporting IQ/OQ/PQ and product launches.
• Lead DOE, SPC, capability studies, and data-driven improvements.
• Troubleshoot molding defects and process instability with root-cause analysis.
• Collaborate across Manufacturing, Quality, Tooling, Materials, and Engineering to resolve issues.
• Support new product introductions, mold qualifications, and scale-up activities.

Skills

Injection molding

Process engineering

Leadership

IQ/OQ/PQ

DOE

SPC

Lean Manufacturing

MRP/ERP

Education

Bachelor's degree in Engineering

Tools

MRP/ERP systems

Job description

Plastic Process Engineering Manager - PSC31926

Location: Wisconsin

Schedule: Full-Time | First Shift

Position Summary

We are seeking an experienced Process Engineering Manager to lead process engineering activities within a high-precision injection molding manufacturing environment. This role is responsible for leading the development, optimization, validation, and continuous improvement of robust manufacturing processes to ensure consistent product quality, process capability, operational efficiency, and scalable production.

The ideal candidate will have strong hands-on expertise in scientific molding, injection molding process development, process validation, and continuous improvement, along with proven leadership experience. Experience with engineered polymers, specialty materials, and Liquid Silicone Rubber (LSR) processes is highly valued. This position requires a technical leader who can effectively manage engineering resources while remaining engaged in solving complex manufacturing and processing challenges.

Key Responsibilities

• Lead, supervise, mentor, and develop the Process Engineering team.
• Establish and drive a culture focused on Safety, Quality, Delivery, and Cost (SQDC).
• Develop, optimize, and maintain robust injection molding processes for high-precision plastic and elastomeric components.
• Apply scientific molding principles to establish capable, repeatable, and production-ready processes.
• Lead process development and qualification activities supporting IQ/OQ/PQ and successful product launches.
• Develop and maintain scientifically established process windows and manufacturing standards.
• Lead DOE, SPC, capability studies, and data-driven process improvement initiatives.
• Troubleshoot complex molding defects, process instability, tooling issues, material concerns, and manufacturing problems through structured root-cause analysis.
• Optimize molding parameters including injection speed, pressure, temperature profiles, cooling, clamp force, cycle time, and other critical process variables.
• Lead process qualification activities and support the implementation of standardized processes across manufacturing operations.
• Establish standard work, process documentation, training requirements, and sustainment plans to support consistent process performance.
• Ensure process development, validation, and documentation activities meet applicable quality systems, customer requirements, and industry standards.
• Partner with Manufacturing, Quality, Tooling, Engineering, Materials, and other cross-functional teams to resolve technical issues and improve operational performance.
• Support new product introductions, mold qualifications, tooling trials, equipment evaluations, and manufacturing scale-up activities.
• Lead significant continuous improvement, Lean Manufacturing, and operational excellence initiatives focused on safety, quality, delivery, productivity, and cost.
• Provide technical support for manufacturing and customer-related processing issues and ensure timely resolution.
• Develop engineering project plans, establish priorities, monitor progress, and communicate project status to stakeholders.
• Prepare and maintain engineering reports, process documentation, work instructions, validation records, and other controlled technical documentation.
• Support cost estimating and quotation activities related to molded components, tooling, equipment, and manufacturing processes.
• Identify, evaluate, and recommend processing equipment, technologies, tooling, and external suppliers aligned with product and process requirements.
• Maintain accurate engineering records and support effective use of MRP/ERP systems and document-control processes.
• Stay current with advancements in injection molding, scientific molding, automation, materials, and manufacturing technologies.
• Develop growth plans for Process Engineers and support the technical development of Process Technicians and Manufacturing Technicians.

Required Qualifications

• 5+ years of hands-on injection molding process engineering experience within a manufacturing environment.
• Demonstrated experience developing, optimizing, troubleshooting, and validating injection molding processes using scientific molding principles.
• Proven experience leading or managing engineering personnel, projects, or technical teams.
• Strong knowledge of process validation, IQ/OQ/PQ, DOE, SPC, capability studies, and root-cause analysis.
• Experience supporting precision molding applications involving engineered polymers and/or Liquid Silicone Rubber (LSR) processes.
• Strong understanding of polymer processing, material behavior, mold/process interaction, tooling, and auxiliary equipment.
• Experience developing manufacturing processes and production standards that meet quality and performance requirements.
• Strong project management skills with the ability to manage multiple priorities and deliver objectives on schedule.
• Experience working with an MRP/ERP system and maintaining disciplined engineering and document-control records.
• Strong analytical, troubleshooting, communication, and problem-solving skills.
• Ability to lead through influence, collaborate cross-functionally, and drive accountability.
• Hands-on leadership approach with a strong bias toward action and continuous improvement.
• Preferred Qualifications
• Experience within medical device, healthcare, life sciences, or other highly regulated manufacturing environments.
• Familiarity with ISO 13485, FDA, GMP, or comparable quality and regulatory requirements.
• RJG Master Molder I or II certification or equivalent scientific molding certification.
• Experience with cleanroom or controlled manufacturing environments.
• Bachelor's degree in Engineering, Plastics Engineering, Manufacturing Engineering, or related technical discipline, or equivalent industry experience.
• Experience with automation, robotics, advanced molding technologies, and integrated manufacturing systems.
• Experience with Lean Manufacturing, Six Sigma, or other structured continuous improvement methodologies.
• Experience supporting technology transfer, process scale-up, or implementation of standardized manufacturing processes.
• Lead and develop the Process Engineering team while establishing clear technical and performance expectations.
• Mentor Process Engineers, Process Technicians, and Manufacturing Technicians in scientific molding principles, troubleshooting, process optimization, and best practices.
• Work cross-functionally with Engineering, Quality, Production, Tooling, Materials, and other teams to ensure successful project execution and sustained process performance.
• Drive technical problem-solving and continuous improvement initiatives from identification through implementation and sustainment.
• Communicate technical findings, project status, risks, and recommendations effectively to both technical and non-technical stakeholders.
• Promote a data-driven culture focused on process capability, repeatability, quality, productivity, and operational excellence.