Process Engineer

Actalent; Phillipsburg (NJ); On-site; USD 100,000 - 115,000; Full time

Benefits offered by this job

9 paid holidays

Tuition reimbursement

Unlimited PTO for salaried employees

Company-sponsored long-term disability

Health, vision, dental, 401k

Job summary

Actalent is hiring a Process Engineer for a permanent, on-site role in Phillipsburg, NJ. The position focuses on developing, validating, and optimizing high-precision injection molding processes in a medical device manufacturing environment, with a strong emphasis on scientific molding, process documentation, and continuous improvement.

You will work cross-functionally to ensure robust, repeatable production in a 24/7 operation, improve process efficiency, and support ECOs related to tooling and

Qualifications

• 5+ years of experience in injection molding operations, preferably 24/7 manufacturing environments.
• Strong knowledge of scientific molding principles and their application to process development.
• Experience with medical devices and large OEMs.
• Experience in process engineering, development, validation, and improvement.
• Ability to perform root cause analysis and implement corrective actions.
• Excellent written and verbal communication for internal and external stakeholders.

Responsibilities

• Develop and optimize injection molding processes using scientific molding methodologies.
• Design, build, and validate processes, molds, and work cells with IQ/OQ/PQ validation.
• Document molding processes, including setup, layouts, and troubleshooting data.
• Lead or participate in cross-functional meetings to drive validation and production projects.
• Troubleshoot production issues, implement process improvements, and support new equipment.
• Create and implement ECOs for processes, tooling, and materials.
• Establish robust process parameters for new and existing jobs.
• Reduce cycle times and improve overall process efficiency.
• Apply statistical process analysis to monitor performance and identify improvements.
• Maintain up-to-date process documentation reflecting best practices.

Skills

Injection molding

Scientific molding

Medical device manufacturing

Process validation

Root cause analysis

Cross-functional collaboration

Documentation

Tools

IQ/OQ/PQ validation

Job description

Job Title: Process Engineer

Job Description

The Process Engineer develops, validates, and optimizes injection molding processes for high-precision plastic products in a medical device manufacturing environment. This role focuses on scientific molding, process documentation, continuous improvement, and cross-functional collaboration to ensure robust, repeatable, and efficient production in a 24/7 operation.

Responsibilities

• Develop injection molding processes using proven scientific molding methodologies to support high-precision plastic products.
• Design, build, and validate injection molding processes, molds, and work cells through IQ, OQ, and PQ validation activities.
• Document molding processes in detail, including mold setup, work cell layout, and troubleshooting information for each validated job.
• Participate in project meetings to keep validation and production projects on track from initiation through completion.
• Support current production needs by troubleshooting molding issues and driving process improvements.
• Support and oversee the introduction and production use of new process equipment.
• Support the creation and implementation of engineering change orders (ECOs) related to processes, tooling, and materials.
• Establish robust, repeatable, and reproducible process parameters for new and existing injection molding jobs.
• Participate in activities aimed at reducing cycle time and improving overall process efficiency.
• Implement statistical process analysis on new and existing products to monitor performance and identify improvement opportunities.
• Develop, maintain, and continuously update process documentation to reflect current best practices and validated conditions.
• Review and refine processing methods to enhance quality, efficiency, and consistency.
• Ensure safety standards and internal policies are followed throughout all manufacturing and engineering activities.
• Leverage industry best practices and apply them to internal systems, processes, and standards.
• Implement Lean Manufacturing principles and drive continuous improvement initiatives across the production environment.
• Maintain a high level of motivation within the area of responsibility and foster a culture of performance and accountability.
• Plan and organize layouts for line changes driven by volume changes or manpower adjustments.
• Maintain regular contact with interdepartmental leaders to provide feedback and alignment when dealing with process or material changes.
• Understand and execute all plant policies and procedures related to production, quality, safety, and employee relations.
• Structure and implement area-specific policies and procedures to ensure safe, efficient operation and strong team performance.
• Develop and maintain positive team member relations based on mutual trust, dignity, respect, fairness, consistency, two-way communication, teamwork, and harmony.
• Apply root cause analysis techniques to identify, diagnose, and resolve process and equipment issues.
• Collaborate closely with production, quality, manufacturing engineering, and tooling teams in a hands-on environment.

Essential Skills

• Minimum of 5+ years of experience in an injection molding operation, preferably in a 24/7 manufacturing or molding environment.
• Strong plastic injection molding experience, including high precision plastic products and tool design for injection molding.
• Knowledge of scientific molding principles and proven ability to apply them to process development and optimization.
• Medical device manufacturing experience and familiarity with requirements for supporting large medical device OEMs.
• Experience in manufacturing process engineering, including process development, validation, and improvement.
• Demonstrated ability to perform root cause analysis and implement effective corrective actions.
• Good written and verbal communication skills for interaction with internal teams and external customers.
• Basic knowledge of manufacturing equipment and advanced ability to read prints and technical drawings.
• Ability to use measuring equipment and apply advanced math skills in process analysis and validation.
• Demonstrated experience in performance development, teaching, leading, mentoring, and/or organizational development.
• Proven success in maintaining positive employee relations and contributing to a collaborative team environment.

Additional Skills & Qualifications

• Experience with equipment support in a manufacturing setting, including troubleshooting and optimization.
• Background in manufacturing engineering with exposure to production, tooling, design, and machining.
• Hands-on experience in process improvement, continuous improvement, and Lean manufacturing initiatives.
• Familiarity with statistical process analysis and data-driven decision-making in a production environment.
• Ability to plan and organize production line layouts in response to volume changes and staffing adjustments.
• Strong teamwork and interpersonal skills, with the ability to work closely with production, quality, and engineering teams.
• Comfort working in a small, highly technical team of engineers focused on injection molding and tooling.

Work Environment

This role operates in a hands-on, 24/7 injection molding and medical device manufacturing environment. Approximately 70% of the time is dedicated to maintaining and optimizing existing processes, while about 30% focuses on developing and validating new processes. The Process Engineer works onsite and interacts frequently with production team members, quality staff, manufacturing personnel, and other engineers. The engineering team is small and highly technical, including several injection molding engineers and a tooling and manufacturing engineer, with leadership that has an engineering Background. The environment emphasizes collaboration, continuous improvement, and open communication. Team members benefit from 9 paid holidays, company-sponsored long-term disability, tuition reimbursement, and unlimited PTO for salaried employees, contributing to a supportive and balanced work culture.

Job Type & Location

This is a Permanent position based out of Phillipsburg, NJ.

Pay And Benefits

The pay range for this position is $100000.00 - $115000.00/yr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

health, vision , dental, 401k - PTO and holiday package

Workplace Type

This is a fully onsite position in Phillipsburg,NJ.

Application Deadline

This position is anticipated to close on Sep 25, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email [e-mail] for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.