Process Engineer

Clayens US LLC; Bolton Estates (TN); On-site; USD 70,000 - 90,000; Full time

Job summary

Clayens US LLC in Greeneville, TN seeks a Process Engineer to develop, optimize, validate, and sustain plastic injection molding processes, ensuring safe, efficient, and high-quality production. This role collaborates with Operations, Quality, Tooling, Maintenance, Engineering, and Program Management to drive continuous improvement.

Responsibilities include process development, mold trials, capability analysis, reducing cycle times and scrap, implementing automation and robotics where

Qualifications

• Bachelor's degree in Engineering or a related technical field.
• 3–7 years in plastic injection molding process engineering or advanced process development.
• Strong knowledge of injection molding equipment, molds, tooling, and resin processing.
• Experience developing and validating molding processes in a manufacturing environment.
• Knowledge of scientific molding principles and process optimization techniques.

Responsibilities

• Develop, establish, validate, and document robust injection molding processes for new and existing products.
• Lead process development activities, including mold trials, process studies, capability analysis, and production validations.
• Analyze molding processes and implement improvements to increase productivity, quality, and overall equipment effectiveness (OEE).
• Troubleshoot molding defects and implement corrective actions.
• Support new product launches, process qualifications, mold validations, and production ramp-ups.

Skills

Analytical skills

Project management

Problem-solving

Reading engineering drawings

GD&T knowledge

Education

Bachelor's degree in Engineering or related field

Tools

Microsoft Office

Manufacturing software systems

Job description

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Process Engineer

Regular Full-Time Greeneville, TN, US

7 days ago Requisition ID: 2326

Salary Range: $70,000.00 To $90,000.00 Annually

Plastic Injection Molding Process Engineer

Job Summary

The Plastic Injection Molding Process Engineer is responsible for developing, optimizing, validating, and sustaining injection molding processes to ensure safe, efficient, and high-quality production. This position works closely with Operations, Quality, Tooling, Maintenance, Engineering, and Program Management teams to improve manufacturing performance, reduce costs, support new product launches, and drive continuous improvement initiatives throughout the molding operation.

Reports To: Operations Manager

Essential Duties and Responsibilities

• Develop, establish, validate, and document robust injection molding processes for new and existing products.
• Lead process development activities, including mold trials, process studies, capability analysis, and production validations.
• Analyze molding processes and implement improvements to increase productivity, quality, and overall equipment effectiveness (OEE).
• Troubleshoot molding defects, including flash, short shots, sink marks, burn marks, splay, warpage, dimensional variation, and cosmetic defects.
• Utilize scientific molding principles and data-driven methodologies to establish and maintain process controls.
• Conduct root cause investigations and implement corrective and preventive actions for process-related issues.
• Support new product launches, process qualifications, mold validations, and production ramp-ups.
• Develop and maintain standard process sheets, work instructions, validation documentation, and engineering records.
• Collaborate with Quality to establish process capability requirements and improve product consistency.
• Identify opportunities to reduce cycle times, scrap, downtime, material consumption, and manufacturing costs.
• Evaluate and implement process improvements involving automation, robotics, vision systems, and auxiliary equipment.
• Partner with Tooling and Maintenance teams to improve mold performance, reliability, and preventive maintenance programs.
• Lead continuous improvement projects utilizing problem-solving methodologies.
• Support production teams by providing technical guidance and training on molding processes and best practices.
• Participate in customer audits, quality investigations, and corrective action activities as required.
• Ensure compliance with safety, environmental, and company policies.

Required Qualifications

• Bachelor's degree in Engineering, Plastics Engineering, Manufacturing Engineering, Mechanical Engineering, or a related technical field.
• Minimum of 3 to 7 years of experience in plastic injection molding process engineering or advanced process development.
• Strong knowledge of injection molding equipment, molds, tooling, and resin processing.
• Experience developing and validating molding processes in a manufacturing environment.
• Knowledge of scientific molding principles and process optimization techniques.
• Experience with root cause analysis, statistical methods, and process capability analysis.
• Ability to read and interpret engineering drawings, GD&T, specifications, and quality standards.
• Proficiency with Microsoft Office and manufacturing software systems.
• Excellent analytical, organizational, and problem-solving skills.
• Strong communication and project management abilities.

Preferred Qualifications

• Bachelor's degree in Plastics Engineering.
• RJG Master Molder Certification or equivalent Scientific Molding certification.
• Experience with automation systems, robotics, and machine vision technologies.
• Experience in automotive, medical, consumer products, or other high-volume injection molding environments.
• Knowledge of DOE (Design of Experiments), Moldflow analysis, and process capability studies.

Knowledge, Skills, and Abilities

• Injection molding process development and optimization.
• Scientific molding and process validation methodologies.
• Plastic resin behavior, material drying, and material handling systems.
• Statistical Process Control (SPC) and process capability analysis.
• Root cause analysis and corrective action implementation.
• Project leadership and cross-functional collaboration.
• Automation and manufacturing technology integration.
• Strong technical writing and documentation skills.
• Excellent verbal and written communication skills.

Physical Requirements

• Ability to stand, walk, and move throughout the manufacturing facility for extended periods.
• Ability to occasionally lift up to 35 pounds.
• Ability to inspect molds, machines, and manufacturing equipment.
• Frequent reaching, bending, and interaction with manufacturing equipment.
• Ability to safely wear required personal protective equipment (PPE).
• Manufacturing environment with exposure to moving machinery, noise, heat, and plastic processing equipment.
• Frequent interaction with production, tooling, engineering, and maintenance personnel.
• Occasional travel may be required to suppliers, customers, or other company facilities.
• May require schedule flexibility to support process trials, launch activities, and critical production needs.

Key Performance Indicators (KPIs)

• Scrap Reduction
• Overall Equipment Effectiveness (OEE)
• Cycle Time Reduction
• First Pass Yield (FPY)
• Process Capability (Cp/Cpk)
• Cost Reduction Achievement
• Downtime Reduction
• New Product Launch Success
• Process Validation Completion
• Customer Quality Performance
• Safety Performance

Success Factors

• Establishes repeatable and robust molding processes.
• Reduces process variation and manufacturing costs.
• Improves productivity and equipment utilization.
• Successfully supports new product introductions and transfers.
• Drives data-based decision-making and continuous improvement.
• Acts as the technical expert for injection molding process performance and optimization.