Senior Process Engineer

Milwaukee Electric Tool Corporation; Town of Mukwonago (WI); On-site; USD 105,000 - 145,000; Full time

Job summary

Milwaukee Tool in Wisconsin is seeking a Senior Process Engineer to act as the technical specialist for plastic injection molding, leading process development, optimization, and long-term sustainment. You will drive manufacturing excellence through data-driven decision making and advanced process control to meet quality, cost, and delivery targets.

You will partner with design, tooling, quality, and operations to ensure manufacturability, define robust process windows, and lead root-cause

Qualifications

• BS in Plastics Engineering Technology or equivalent.
• 5+ years of hands-on thermoplastics processing experience.
• RJG Master Molder I/II strongly preferred.
• Experience in scientific molding, process validation, and troubleshooting.
• Strong understanding of mold design, tooling principles, material data, molding machines, auxiliaries, and process monitoring tools.
• Robotic programming and troubleshooting required.
• Proficiency in CAD/CAE preferred.
• Six Sigma Yellow or Green belt is a plus.

Responsibilities

• Develop, optimize, and sustain injection molding processes using scientific molding principles to achieve quality, delivery, and cost targets.
• Define and validate robust process windows, control strategies, and safeguards using DOE, Cp/Cpk, and statistical methods.
• Support tooling lifecycle activities, including design reviews, build validations (T0/T1/Tn), and continuous process/tooling improvements.
• Drive root cause analysis and corrective/preventive actions for molding-related defects, leveraging data to eliminate systemic issues.
• Partner cross-functionally with design, tooling, quality, and operations to ensure manufacturability and performance targets are met.
• Identify trends through process and quality data to drive continuous improvement and defect reduction initiatives.
• Create and maintain standardized process documentation (SOPs, control plans) to ensure repeatability and scalability.
• Provide technical leadership, training, and support to manufacturing teams to strengthen process capability and execution.

Skills

Data-driven decision making

Analytical problem solving

Cross-functional collaboration

Education

BS in Plastics Engineering Technology or equivalent

Tools

RJG Master Molder I/II

CAD/CAE

Job description

WE CREATE EMPOWERED LEADERS! At Milwaukee Tool, we believe our people and our culture are the driving forces behind our success.

As a Senior Process Engineer, you will serve as the technical specialist for plastic injection molding - leading process development, optimization, and long-term sustainment. You will drive manufacturing excellence through data-driven decision-making, advanced process control, and continuous improvement.

Key Responsibilities:

• Develop, optimize, and sustain injection molding processes using scientific molding principles to achieve quality, delivery, and cost targets.

• Define and validate robust process windows, control strategies, and safeguards using DOE, Cp/Cpk, and statistical methods.

• Support tooling lifecycle activities, including design reviews, build validations (T0/T1/Tn), and continuous process/tooling improvements.

• Drive root cause analysis and corrective/preventive actions for molding-related defects, leveraging data to eliminate systemic issues.

• Partner cross-functionally with design, tooling, quality, and operations to ensure manufacturability and performance targets are met.

• Identify trends through process and quality data to drive continuous improvement and defect reduction initiatives.

• Create and maintain standardized process documentation (SOPs, control plans) to ensure repeatability and scalability.

• Provide technical leadership, training, and support to manufacturing teams to strengthen process capability and execution.

Education and Experience Requirements

• BS in Plastics Engineering Technology or equivalent

• 5+ years of hands-on thermoplastics processing experience.

• RJG Master Molder I/II strongly preferred.

• Demonstrated expertise in scientific molding, process validation, and process troubleshooting.

• Strong understanding of mold design, tooling principles, material data, molding machines, auxiliaries, and process monitoring tools.

• Robotic programming and troubleshooting required.

• Strong problem-solving skills (A3 / 5 Why / 8D) and attention to detail are essential.

• Preferred Proficiency in CAD/CAE

• Great to have Six Sigma Yellow or Green belt.

Milwaukee Tool is an equal opportunity employer.