Process Engineer

Actalent; Kentucky; On-site; USD 70,000 - 100,000; Full time

Job summary

Actalent is seeking a Process Engineer to optimize mold designs and lead plastic extrusion and molding programs from pilot to full-scale production.

You will apply DOE, SPC, and Mold Flow analyses, collaborate with engineering, operations, quality, and customers, and drive cost-effective manufacturing improvements with a focus on quality and reliability.

Qualifications

• Bachelor’s degree in Engineering or equivalent experience.
• Approximately five years in manufacturing processes and design engineering.
• Hands-on experience with plastics processing and injection molding.
• Strong understanding of modern injection molding techniques.
• Familiarity with DOE, SPC, Mold Flow and FMEA.
• Systematic problem solving with data-driven decisions.
• Lean manufacturing principles experience.

Responsibilities

• Perform mold process development using a scientific approach to optimize processes.
• Develop, implement and document procedures for setup through production scheduling.
• Refine process parameters on existing molds to ensure stability and repeatability.
• Provide guidance to supervisors and quality personnel for mold maintenance and repair.
• Build customer relationships by delivering sampling results and solutions.
• Recommend designs for equipment and support tooling development.
• Train others on equipment use and maintenance such as robots and hot runners.
• Evaluate processing equipment to identify productivity and cost opportunities.
• Stay current on plastics processing methods and tools for continuous improvement.
• Create and maintain documentation for samples, processes, items, issues, and data.
• Support new business development with tooling design and sourcing for cost objectives.
• Plan and run experiments to improve procedures and part designs; perform DOEs.

Skills

Mold design optimization

Plastics processing

DOE / SPC / FMEA

Injection molding

3D CAD SolidWorks

Project management

Teamwork & communication

Education

Bachelor’s degree in Engineering

Master mold certificate

Tools

SolidWorks

Job description

Job Description

Job Title: Process Engineer

Job Description

This Process Engineer role focuses on optimizing mold designs and implementing plastic extrusion and plastic molding manufacturing processes from pilot through full-scale operations. The position drives efficiency, quality, and functionality of molded products by developing robust processes, conducting experiments and tests, and supporting tooling and equipment implementation. The Process Engineer serves as a subject matter expert for new and existing products, working closely with engineering, operations, quality, and customers to ensure stable, repeatable, and cost-effective manufacturing.

Responsibilities

• Perform mold process development using a scientific approach to achieve optimal processes that meet quality, productivity, and reliability specifications.
• Develop, implement, and document procedures to define and report process parameters from setup through production scheduling, ensuring consistent and reliable operations.
• Establish and refine manufacturing process parameters on existing molds using techniques such as mold balance analysis, gate freeze studies, and relative viscosity studies to ensure stable and repeatable processes.
• Provide direction and technical guidance to supervisors and quality personnel to support mold maintenance, repair, and cleaning while fostering a relationship of trust and collaboration.
• Build and maintain positive customer relationships by delivering effective sampling results and providing solutions to production problems.
• Recommend designs for special equipment and assist production teams with product and process research and development programs.
• Maintain and train others on the proper maintenance and use of product-specific equipment such as robots, hot runner systems, and related tooling.
• Evaluate plastic processing and support equipment to identify opportunities for productivity improvement, quality enhancement, and cost reduction.
• Stay current on methods, systems, and equipment in plastics processing to continuously improve quality and productivity.
• Create and maintain accurate documentation for all samples, processes, production items, issues, and related technical information.
• Support new business development, engineering, and operations as a subject matter expert in designing, developing, and sourcing tooling that meets functional and cost objectives for new products.
• Plan and run experiments and tests to improve manufacturing procedures, processes, and part designs, ensuring data-driven decision-making.
• Execute designed experiments (DOEs), analyze results, report findings, and create or update standard operating procedures (SOPs) based on outcomes, while maintaining complete observation and experiment records.

Essential Skills

• Bachelor’s degree in an Engineering discipline or equivalent experience.
• Approximately five years of experience in manufacturing processes, design engineering, automation, and project management, with demonstrated ability to develop unique and innovative design solutions.
• Hands-on experience with plastics processing and plastic injection molding, including process improvement and process engineering.
• Strong understanding of modern injection molding techniques and processes.
• Familiarity with scientific analysis methods such as Design of Experiments (DOE), Statistical Process Control (SPC), Mold Flow analysis, and Failure Modes and Effects Analysis (FMEA).
• Proven ability to use a systematic approach to problem solving, including analyzing issues and evaluating alternative solutions.
• Demonstrated ability to start and persist with specific courses of action, showing high motivation and a strong sense of urgency.
• Experience with 3D CAD tools, with preference for SolidWorks, to support design and process development activities.
• Strong organizational and planning capabilities with exceptional problem prevention and problem-solving skills.
• High attention to detail with the ability to meet deadlines on complex projects and perform effectively in a fast-paced environment.
• Excellent teamwork and communication skills, with the ability to work through others to get things done and meet commitments.
• Ability to establish effective working relationships at all levels within the organization and with customers and suppliers.

Additional Skills & Qualifications

• Bachelor’s degree specifically in Plastics Engineering is highly desirable.
• Master mold certificate is a plus.
• Experience working in plastics or injection molding environments with at least five years of process experience.
• Experience applying Lean manufacturing princ