Senior Process Engineer

Nordson EFD LLC; East Providence (RI); On-site; USD 110,000 - 140,000; Full time

Job summary

Qualifications

• Bachelor’s or equivalent with ABET-accredited program.
• 10+ years hands-on injection molding/plastics processing experience.
• Proven mold design, tooling specs, and process optimization experience.
• Strong knowledge of SPC, process validation, and root-cause analysis.

Responsibilities

• Provide day-to-day engineering support for injection molding to maintain yield and quality.
• Troubleshoot molding defects and optimize process parameters.
• Develop and refine process sequences and tooling specs affecting performance.
• Lead tooling design, modification, validation, and maintenance including molds and fixtures.
• Coordinate with vendors for mold maintenance and parts and manage changes.
• Apply SPC methods to improve consistency and drive corrective actions.
• Support DFMs and new product introductions from design to production.

Skills

Injection molding

Process optimization

SPC

Mold design

Cross-functional leadership

Project management

Education

ABET plastics eng.

Tools

SAP

Mold flow analysis

Job description

Nordson EFD, a global leader in Engineered Fluid Dispensing, is seeking an experienced and highly motivated individual to join our team. We are committed to creating a diverse and inclusive workplace, and we are looking for candidates who share that same commitment.

SUMMARY OF THE ROLE

As a member of our team, you will have the opportunity to work in a dynamic and collaborative environment, where your ideas and contributions will be valued and respected.

JOB SUMMARY

The Sr Manufacturing Engineer will be responsible for providing day-to-day engineering support for injection molding processes, with a focus on maintaining and improving yield, product quality, and overall manufacturing efficiency. This role will lead tooling design, validation, and maintenance activities while partnering with internal teams and external vendors to ensure optimal process performance. The ideal candidate must possess hands-on experience with injection molding and plastics processing, combined with strong analytical and cross-functional collaboration skills.

ESSENTIAL JOB DUTIES & RESPONSIBILITIES

Process Engineering & Optimization

• Provide day-to-day engineering support for injection molding processes to maintain and improve yield and product quality.
• Troubleshoot molding defects and optimize process parameters.
• Develop and refine process sequences and tooling specifications that impact product performance.
• Support targeted projects including defining and documenting product and processing parameters, capability, cost reductions, and manufacturing.

Tooling & Equipment Management

• Evaluate and maintain mold components including cavities, mold bases, and core pins, with direct impact on process output.
• Lead tooling design, modification, validation, and maintenance activities, including molds, fixtures, and gauges, to support production and product quality.
• Partner with external vendors to manage mold maintenance and spare parts, ensuring timely repairs and availability.
• Coordinate engineering changes and mold repairs with both internal and external resources.
• Ensure the effective design of production tooling.
• Support new production tooling design, runs and changeovers.

Quality & Statistical Process Control

• Apply and develop statistical process control (SPC) methods to improve consistency and reduce variation.
• Make MRB dispositions for discrepant materials and drive root cause analysis and resulting corrective actions.
• Provide technical guidance and support investigations for process-related deviations, change control, and operational excellence projects.
• Work closely with Quality Control and Production teams on process and product development, as well as continuous improvement initiatives.

Product Development & Design for Manufacturability

• Collaborate cross-functional to provide design for manufacturability (DFM) guidance to engineering teams.
• New product development including engineering concept, design analysis, calculations, and problem solving.
• Perform activities associated with the design and qualification of new and existing products and processes.
• Ensure a thorough and effective transition of new products and processes into production.

Documentation & Validation

• Create, execute validation protocols, and write validation summary reports and draft new procedures, SOPs, and protocols, as well as training of staff on these expectations.
• Write technical reports to support process development data.

Project Management & Communication

• Interact with customers, vendors, toolmakers, and outside engineering personnel.
• Participate in and coordinate project meetings to keep projects on track until completion of validation and transfer to production.
• Support production on CAPEX projects for production facility and equipment improvements to increase production efficiency and reduce cost.
• Communicate operational status regularly to senior management and corporate management, as required and appropriate, through written documents and formal/informal oral presentations.

Troubleshooting & Corrective Action

• Troubleshoot process equipment and ensure that equipment works to its specifications and appropriate capacities.
• Troubleshoot and diagnose mold and molding problems and effectively communicate solutions.
• Provide hands-on support for equipment, process, and material troubleshooting.
• Support day-to-day manufacturing operations by troubleshooting process issues and implementing solutions.
• Responsible for troubleshooting and providing corrective action directives.
• Assist production teams to ensure on-time delivery and maintain quality standards.

Education & Experience Requirements

• Bachelor’s in engineering or Associates in Plastics or Manufacturing Engineering from an ABET accredited College or University
• 10+ years of hands-on experience with injection molding and plastics processing.
• Proven experience with mold design, tooling specifications, and process optimization
• Strong understanding of SPC, process validation, and root cause analysis methodologies
• Proficient in Microsoft Office Excel, Word and PowerPoint.

SKILLS & ABILITIES

• Experience with design for manufacturability (DFM) principles
• Familiarity with GMP documentation and regulatory requirements
• Knowledge of CAPEX project management, SAP, tooling and equipment justification
• Experience working with domestic and overseas tooling sources
• Strong communication and presentation skills for interacting with customers, vendors, and senior management
• Proficiency in mold flow analysis and process simulation software is a plus
• Analytical problem-solving and troubleshooting mindset
• Cross-functional collaboration and team leadership
• Project management and coordination
• Technical documentation and report writing
• Continuous improvement and operational excellence orientation

Working Conditions & Physical Demands

Mixed environment; office, laboratory & manufacturing. This position operates in a manufacturing environment and may require occasional travel to vendors or customer sites. The role involves hands-on work on the production floor, including exposure to machinery and noise levels typical of an injection molding facility. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Travel Required

None Minimal Estimated: 10% Domestic and International

Equal Employment Opportunity

Nordson Corporation provides equal employment opportunity to all applicants and employees.

No person is to be discriminated against in any aspect of the employment relationship due to race, religion, color, sex, age, national origin, disability, citizenship status, marital status, veteran status or any other reason prohibited by law.

All employment offers are contingent upon successful completion of our pre-employee drug screening and background/criminal check, consistent with applicable laws.

About Nordson EFD

Nordson EFD is a world-leading designer and manufacturer of fluid dispensing systems and single-use fluid packaging. By joining our team today, you will help us bring innovative ideas to life.

Nordson EFD is a global team that works to create systems and consumables that improve the fluid dispensing process. We offer a supportive culture in a growing and dynamic work environment. Whether you're just beginning your career or you're a seasoned professional, there's a place for you to belong at Nordson EFD.

We offer hourly and salary positions in production, maintenance, customer service, quality, engineering, and more. We actively invest in our teams to help you build your skillsets and advance your career. At Nordson, we believe that anything is possible. We empower our global team of employees to engineer, manufacture, and market innovative products and systems that are essential to everyday life.

These differentiated products and systems are used for precision dispensing and processing and serve a variety of end markets, including packaging, transportation, medical, and electronics. Founded in 1954, we are guided by our values of integrity, respect for people, customer passion, energy, and excellence. We care for our employees and provide them with opportunities to advance their careers and make an impact, inside and outside of work.

Nordson is headquartered in Westlake, Ohio, and has direct operations in more than 35 countries to support our products and systems with application expertise and a direct global sales and service organization.