Senior Process Engineer - Plastics

Michael Page; Seymour (CT); On-site; USD 110,000 - 145,000; Full time

Benefits offered by this job

Employee ownership

Career growth

Mentorship opportunities

Advanced molding tech

Job summary

Michael Page is seeking an experienced Senior Process Engineer to lead injection moulding process development, validation, and continuous improvement in a highly advanced manufacturing environment. You will drive quality, throughput, and efficiency while supporting new product launches and production operations.

The role requires 8+ years of plastics process engineering excellence, strong scientific moulding knowledge, and cross‑functional collaboration with Quality and Manufacturing teams.

Qualifications

• 8+ years of process engineering experience in plastics manufacturing.
• Demonstrated experience in developing, validating, optimising, and troubleshooting injection moulding processes.
• Strong knowledge of scientific moulding, decoupled moulding, process windows, tooling, materials, and secondary operations.
• Experience with mould sampling, process validation, capability studies, root cause analysis, CAPA, and corrective action processes.
• Knowledge of Lean Manufacturing, Six Sigma, DOE, SPC, PFMEA, and control plans.
• Experience with ERP/MES systems and process data analysis tools.
• Excellent communication, leadership, mentoring, and project management skills.
• Experience writing, reading, and interpreting technical engineering and manufacturing documentation.

Responsibilities

• Develop, optimise, and troubleshoot injection moulding processes for new and existing products.
• Lead mould sampling, process development, validation activities, and production launches.
• Analyse process data to improve quality, efficiency, cycle times, and process capability.
• Collaborate with Quality teams to establish process controls and monitoring systems.
• Investigate and resolve issues related to moulding processes, tooling, materials, automation, and equipment.
• Create and maintain process documentation, setup standards, work instructions, and validation records.
• Support PFMEAs, Control Plans, process flow documentation, and manufacturing standards.
• Participate in mould design reviews, print reviews, and material evaluations.
• Provide technical guidance on tooling, automation, equipment, and manufacturing process requirements.
• Design and execute DOE studies, process validations, and capability assessments.
• Drive continuous improvement initiatives focused on cost reduction, scrap reduction, productivity, and operational excellence.
• Support KPI reporting and analysis relating to efficiency, downtime, OEE, cycle time, scrap, and process capability.
• Act as a technical expert for troubleshooting production challenges and quality concerns.
• Mentor and develop Process Technicians, Setup Technicians, and Operations personnel on scientific moulding and process control methodologies

Skills

Injection moulding

Process development

DOE

Six Sigma

Lean Manufacturing

PFMEA

Control Plans

Root cause analysis

CAPA

Project management

Mentoring

Leadership

Communication

Education

Bachelor's degree in Manufacturing/Mechanical/Plastics/Industrial Engineering

Tools

Moldflow

RJG/eDART

CAD software

Job description

We're seeking an experienced Senior Process Engineer to lead injection moulding process development, optimisation, validation, and continuous improvement initiatives within a highly advanced manufacturing environment. You'll play a critical role in improving quality, efficiency, throughput, and overall manufacturing performance while supporting new product launches and production operations.

Client Details

Our client is a highly respected employee‑owned manufacturing organisation known for its engineering excellence, innovation, and commitment to continuous improvement. The business partners with leading global organisations on complex, high‑precision products and offers employees the opportunity to make a meaningful impact while developing long‑term careers.

Description

• Develop, optimise, and troubleshoot injection moulding processes for new and existing products using scientific moulding principles.
• Lead mould sampling, process development, validation activities, and production launches.
• Analyse process data to improve product quality, efficiency, cycle times, and process capability.
• Collaborate closely with Quality teams to establish effective process controls and monitoring systems.
• Investigate and resolve issues relating to moulding processes, tooling, materials, automation, and equipment.
• Create and maintain process documentation, setup standards, work instructions, and validation records.
• Support the development and maintenance of PFMEAs, Control Plans, process flow documentation, and manufacturing standards.
• Participate in mould design reviews, print reviews, and material evaluations.
• Provide technical guidance on tooling, automation, equipment, and manufacturing process requirements.
• Design and execute DOE studies, process validations, and capability assessments.
• Drive continuous improvement initiatives focused on cost reduction, scrap reduction, productivity, and operational excellence.
• Support KPI reporting and analysis relating to efficiency, downtime, OEE, cycle time, scrap, and process capability.
• Act as a technical expert for troubleshooting production challenges and quality concerns.
• Mentor and develop Process Technicians, Setup Technicians, and Operations personnel on scientific moulding and process control methodologies

Profile

• Bachelor's degree in Manufacturing, Mechanical, Plastics, Industrial Engineering, or a related discipline.
• 8+ years of process engineering experience within plastics manufacturing, including strong injection moulding expertise.
• Demonstrated experience developing, validating, optimising, and troubleshooting injection moulding processes.
• Strong understanding of scientific moulding, decoupled moulding, process windows, tooling, materials, and secondary operations.
• Experience with mould sampling, process validation, capability studies, root cause analysis, CAPA, and corrective action processes.
• Knowledge of Lean Manufacturing, Six Sigma, DOE, SPC, GD&T, PFMEA, and control plans.
• Experience working with ERP/MES systems and process data analysis tools.
• Strong communication, leadership, mentoring, project management, and problem‑solving skills.
• Experience writing, reading, and interpreting technical engineering and manufacturing documentation.

Preferred Experience

• Experience within ISO 13485 or similarly regulated manufacturing environments.
• Familiarity with CAD software and process simulation tools.
• Experience with Moldflow, RJG/eDART, cavity pressure monitoring, or similar technologies.
• Background supporting medical devices, highly regulated products, or advanced manufacturing industries.
• Lean Six Sigma certification or advanced continuous improvement training

Job Offer

• Employee ownership programme with a direct stake in company success.
• Opportunity to work on technically challenging and innovative manufacturing projects.
• Strong exposure to advanced injection moulding technologies and engineering best practices.
• Collaborative culture that values continuous improvement, innovation, and professional growth.
• Excellent opportunity to influence manufacturing performance, mentor others, and progress your engineering career

MPI does not discriminate on the basis of race, color, religion, sex, sexual orientation, gender identity or expression, national origin, age, disability, veteran status, marital status, or based on an individual's status in any group or class protected by applicable federal, state or local law. MPI encourages applications from minorities, women, the disabled, protected veterans and all other qualified applicants.