Process Development Engineer

ExecuSource, Inc.; Harlingen, Northern (TX, KY); Hybrid; USD 85,000 - 110,000; Full time

Job summary

ExecuSource, Inc. in Harlingen, TX is seeking an experienced Process Engineer to lead continuous improvement and new molding process development in a plastics manufacturing environment.

You will collaborate with Operations, Maintenance, Quality, Engineering, and production teams to improve performance, reduce scrap and downtime, and support new launches. The role involves APQP activities, robotics setup, tooling management, and hands-on process troubleshooting across multiple production cells.

Qualifications

• Higher education or technical training in a Quality- or Engineering-related field; high school diploma or GED required.
• Injection molding experience strongly aligned with responsibilities of this role.
• Experience with computers and related systems; formal computer training is preferred.
• Quality systems experience is preferred.
• Experience with customer communication is preferred.
• Hands-on experience with process troubleshooting, continuous improvement, root cause analysis, and corrective/preventive actions.
• Experience supporting tooling, robotics, manufacturing cells, APQP, Gage R&R, Cpk studies, or production launches is highly relevant.

Responsibilities

• Lead and support root cause verification, corrective actions, and preventative actions related to NCRs and CARs.
• Drive plant improvements focused on scrap reduction, unscheduled downtime, process interruptions, cell setup, regrind usage, and processing parameters.
• Partner with Maintenance to diagnose and resolve process- and equipment-related issues.
• Support APQP activities and develop new molding processes, including mold rheology, fill-at-transfer studies, tooling, material drying, hot runners, and temperature control units.
• Program and modify robots and support robotic/work-cell setup for new and transfer programs.
• Coordinate new and transfer tool sampling, production-readiness activities, job books, tooling PM files, and post-processing standards.
• Support the first three production runs through setup assistance, training, process monitoring, performance analysis, and feedback to the APQP team.
• Assist with Gage R&R and Cpk studies and train production personnel on new launches, products, processes, and technology.
• Maintain process-development project information and update job instructions as processes are developed or changed.
• Travel as needed for transfer-tool fact-finding, tooling reviews, functional samples, and related process-development activities.

Skills

Injection molding experience

Root cause analysis

Continuous improvement

Process troubleshooting

Cross-functional collaboration

Gage R&R

Cpk studies

APQP

Robotics setup

Education

Engineering or Quality-related degree or technical training

Tools

Robotics

APQP

Gage R&R

Job description

Process Engineer - Plastic Injection Molding / Continuous Improvement

Location: Harlingen, TX

Schedule: 8am-5pm Monday-Friday- onsite

Our client is a well-established plastics manufacturing organization focused on process improvement, quality, operational performance, and the successful launch and transfer of injection-molded products. The organization offers the opportunity to make a meaningful impact through hands-on process development, continuous improvement, and cross-functional collaboration.

They are looking for an experienced Process Engineer who can support both continuous improvement initiatives and new process development within a manufacturing environment. This role will partner closely with Operations, Maintenance, Quality, Engineering, and production teams to improve performance, reduce scrap and downtime, support new launches, and strengthen manufacturing processes.

What you get to do:

• Lead and support root cause verification, corrective actions, and preventative actions related to NCRs and CARs.
• Drive plant improvements focused on scrap reduction, unscheduled downtime, process interruptions, cell setup, regrind usage, and processing parameters.
• Partner with Maintenance to diagnose and resolve process- and equipment-related issues.
• Support APQP activities and develop new molding processes, including mold rheology, fill-at-transfer studies, tooling, material drying, hot runners, and temperature control units.
• Program and modify robots and support robotic/work-cell setup for new and transfer programs.
• Coordinate new and transfer tool sampling, production-readiness activities, job books, tooling PM files, and post-processing standards.
• Support the first three production runs through setup assistance, training, process monitoring, performance analysis, and feedback to the APQP team.
• Assist with Gage R&R and Cpk studies and train production personnel on new launches, products, processes, and technology.
• Maintain process-development project information and update job instructions as processes are developed or changed.
• Travel as needed for transfer-tool fact-finding, tooling reviews, functional samples, and related process-development activities.

What you need to succeed:

*This role requires plastic injection molding experience*

• Applicable manufacturing/process-development experience; injection molding experience is strongly aligned with the responsibilities of this role.
• Higher education or technical training in a Quality- or Engineering-related field; high school diploma or GED required.
• Experience with computers and related systems; formal computer training is preferred.
• Quality systems experience is preferred.
• Experience with customer communication is preferred.
• Hands-on experience with process troubleshooting, continuous improvement, root cause analysis, and corrective/preventative actions.
• Experience supporting tooling, robotics, manufacturing cells, APQP, Gage R&R, Cpk studies, or production launches is highly relevant.

What's in it for you:

• Opportunity to make a direct impact on plant performance, process reliability, quality, and new product launches.
• Hands-on role with exposure to Operations, Engineering, Quality, Maintenance, and production teams.
• Opportunity to support process development, automation, tooling, and continuous improvement initiatives.
• Compensation, benefits, and schedule details will be provided as they become available.

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