Principal Process Engineer - Thermoplastic Injection Molding

flex; Libertyville (IL); On-site; USD 119,000 - 165,000; Full time

Job summary

Flex is seeking a Principal Process Engineer specializing in Thermoplastic Injection Molding to join their team in Libertyville, IL. The role involves improving process engineering capabilities to enhance cost, quality, and delivery in a manufacturing environment. The ideal candidate will have extensive experience in process development and possess strong analytical skills to troubleshoot and improve manufacturing techniques.

Benefits

Full range of medical, dental, and vision plans

Life Insurance

Short-term and Long-term Disability

Matching 401(k) Contributions

Vacation and Paid Sick Time

Tuition Reimbursement

Qualifications

• Typically requires 10-15 years of process development experience.
• Experience with Tooling and Scientific/Thermoplastic Injection Molding.
• RJG / E-Dart experience preferred.

Responsibilities

• Recognize and define manufacturing processes and technologies.
• Evaluate and implement process control methodologies.
• Provide training to production personnel.

Skills

Attention to detail

Data analysis

Education

Degree in plastics/injection molding

Tools

Excel

Minitab

Job description

Job Posting Start Date 06-17-2025 Job Posting End Date 08-31-2025

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world. A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment. If you are excited about a role but don't meet every bullet point, we encourage you to apply and join us to create the extraordinary. Job Summary

To support our extraordinary teams who build great products and contribute to our growth, we’re looking to add a Principal Process Engineer - Thermoplastic Injection Molding located in Libertyville, IL.

Reporting to the Process Engineering Manager, the Principal Process Engineer - Thermoplastic Injection Molding is responsible for process engineering capabilities focused on cost, quality and delivery improvements in order to hold up a manufacturing organization.

What a typical day looks like:

• Recognize the manufacturing process, technologies, techniques and the product.
• Define, implement and evaluate proposed designs and processes for manufacturability.
• Have the capability to singly or with other engineering stakeholders identify root causes of failures in the manufacturing process
• High level participation in daily production activities and effective problem solving on daily issues
• Prepare justification, purchase and implement capital equipment for production.
• Hold up and oversee new process equipment production.
• Hold up the raising and introduction of engineering change orders (ECOs).
• Establish robust, repeatable and reproducible process parameters
• Develop, implement and take ownership of process control methodologies.
• Trouble shoot process related issues.
• Participate in activities pertaining to cycle time and process improvements.
• Evaluate and select various engineered materials.
• Implement statistical process research on new and existing products.
• Implement safety, productivity and give in improvements.
• Improve manufacturing techniques and through put.
• Provide continuous development of manufacturing techniques that will improve in-house capabilities and gives in.
• Develop and maintain process documentation.
• Review processing methods.
• Interface with production of all activities associated with new process implementation and transfer.
• Assist in the development of training and provide training to production personnel during new technology transfer.
• Provide equipment maintenance and repair hold up as required.
• Guide cost improvement/reduction programs.

The experience we’re looking to add to our team:

• Typically requires 10- 15 years’ experience of process development (IQ, OQ PQ), Tooling, and Scientific / Thermoplastic Injection Molding.
• Attention to detail in relation to manufacturing and injection molding processes.
• RJG / E-Dart experience preferred.
• Experience in Class 7 or 8 Cleanrooms preferred.
• Degree or equivalent work experience and training in plastics/injection molding.
• Data analysis / statistics with excel, Minitab, or similar platform preferred.

What you'll receive for the great work you provide:

• Full range of medical, dental, and vision plans
• Life Insurance
• Short-term and Long-term Disability
• Matching 401(k) Contributions
• Vacation and Paid Sick Time
• Tuition Reimbursement

Pay Range (Applicable to Illinois) $119,300.00 USD - $164,100.00 USDAnnual Job CategoryProduction Engineering Relocation: Eligible for domestic relocation only

Is Sponsorship Available?

Yes Flex is an Equal Opportunity Employer and employment selection decisions are based on merit, qualifications, and abilities. We do not discriminate based on: age, race, religion, color, sex, national origin, marital status, sexual orientation, gender identity, veteran status, disability, pregnancy status, or any other status protected by law. We're happy to provide reasonable accommodations to those with a disability for assistance in the application process. Please email [e-mail] and we'll discuss your specific situation and next steps (NOTE: this email does not accept or consider resumes or applications. This is only for disability assistance. To be considered for a position at Flex, you must complete the application process first).