Process Development Engineer

tsu.edu; Houston (TX); On-site; USD 90,000 - 130,000; Full time

Job summary

PRISM, backed by Berkshire Hathaway, seeks a Process Development Engineer with hands-on plastic injection molding experience to lead process development, optimize performance, and support new product launches. You will develop and validate molding processes, run mold trials, and maintain manufacturing standards.

Responsibilities include APQP/PPAP support, process documentation, data analysis, and cross-functional collaboration to reduce scrap, downtime, and cycle times while driving

Qualifications

• Hands-on injection molding experience is required.
• Strong understanding of scientific molding and process development.
• Experience troubleshooting molding defects and optimizing processes.
• Knowledge of mold setup, tooling, resin handling, and automation.
• Experience developing process documentation and manufacturing standards.
• Ability to analyze data and implement improvements.
• Strong communication and problem-solving skills.

Responsibilities

• Lead injection molding process development for new and existing programs.
• Establish and optimize scientific molding parameters and process windows.
• Conduct mold trials, sampling, and production validations.
• Support APQP/PPAP activities for new launches and transferred programs.
• Develop and maintain process documentation and standards.
• Analyze process capability data and support Gage R&R and CpK studies.
• Identify improvements to reduce scrap, downtime, and cycle times.
• Lead root cause investigations and corrective actions for molding issues.
• Audit molding processes for compliance and validated parameters.
• Collaborate with Operations, Maintenance, and Engineering teams; travel for transfers.

Skills

Hands-on injection molding

Scientific molding

Data analysis

Troubleshooting defects

Process documentation

Communication skills

Education

Associate's or Bachelor's in Engineering

Scientific Molding certification

Tools

Robotics programming

Job description

As part of the global industrial organization Marmon Holdings, backed by Berkshire Hathaway, you'll have the opportunity to make a direct impact on manufacturing performance, new product launches, and process innovation. At PRISM, we are committed to continuous improvement, operational excellence, and investing in talented professionals who are passionate about plastics manufacturing.

We are seeking a highly skilled Process Development Engineer with hands-on plastic injection molding experience to lead process development, optimize manufacturing performance, and support new product launches. This role is ideal for someone who enjoys solving complex molding challenges, improving efficiencies, reducing scrap, and driving best-in-class processing standards.

What You'll Do

Lead Injection Molding Process Development

• Develop, validate, and optimize injection molding processes for new and existing programs
• Establish scientific molding parameters utilizing:
  • In-Mold Rheology
  • Decoupled Molding Techniques
  • 95% Fill Studies
  • Gate Seal Analysis
  • Process Window Development
• Conduct mold trials, sampling activities, and production validations
• Support APQP and PPAP activities for new product launches and transferred programs
• Develop and maintain process documentation, job books, and manufacturing standards
• Analyze process capability data and support Gage R&R and Cpk studies

Drive Continuous Improvement

• Identify and implement improvements that reduce:
  • Scrap
  • Downtime
  • Process variation
  • Cycle times
• Lead root cause investigations and corrective actions for molding-related quality issues
• Participate in NCR and CAR activities, ensuring effective corrective and preventative actions
• Audit molding processes to ensure compliance with established standards and validated parameters
• Partner with Operations and Maintenance teams to troubleshoot process and equipment challenges

Support Manufacturing Launches

• Lead setup and validation of new manufacturing cells including:
  • Injection molds
  • Material handling systems
  • Drying equipment
  • Hot runner controls
  • Temperature control units (TCUs)
  • Automation and robotics
• Program and modify robotic systems to support efficient production
• Develop and improve end-of-arm tooling, fixtures, and automation solutions
• Support the first three production runs for new programs, including:
  • Training operators and technicians
  • Monitoring process performance
  • Auditing process compliance
  • Analyzing production results
  • Driving corrective actions as needed

Collaborate Across Functions

• Work closely with Engineering, Quality, Operations, Maintenance, and Production teams
• Participate in tooling design reviews and launch planning activities
• Support customer and supplier interactions when necessary
• Travel occasionally to support tooling transfers, launch activities, and process evaluations

What We're Looking For

Required Qualifications

• Hands-on experience in plastic injection molding is required
• Strong understanding of scientific molding principles and process development
• Experience troubleshooting molding defects and optimizing processes
• Knowledge of mold setup, tooling, resin handling, drying requirements, and automation systems
• Experience developing process documentation and manufacturing standards
• Ability to analyze data and implement process improvements
• Strong communication and problem-solving skills

Preferred Qualifications

• Experience with APQP, PPAP, and quality management systems
• Robotics programming and automation experience
• Experience leading continuous improvement initiatives in a manufacturing environment
• Customer-facing project or technical support experience
• Understanding of statistical process control, capability studies, and validation activities

Education

• High School Diploma or GED required
• Associate's or Bachelor's degree in Engineering, Plastics Technology, Manufacturing Technology, or a related field preferred
• Scientific Molding certification or equivalent plastics processing training is highly valued

Why Join PRISM?

• Be part of a Berkshire Hathaway company with long-term stability and growth opportunities.
• Work with advanced injection molding technologies, automation, and new product launches.
• Have a direct impact on manufacturing performance and operational excellence.
• Collaborate with experienced engineering and operations professionals.
• Competitive compensation and comprehensive benefits package.

Important Note

Candidates must have prior hands-on plastic injection molding experience to be considered for this role. Applicants without injection molding experience will not be considered.

PRISM is an Equal Opportunity Employer and considers all qualified applicants without regard to protected status. Reasonable accommodations are available throughout the hiring process.