Senior Project Engineer - Plastic Extrusion

Sonoco; Forest City (NC); On-site; USD 85,000 - 110,000; Full time

Job summary

Sonoco is seeking a hands-on Plastics Process Engineer to qualify extrusion tools and develop manufacturing standards at our Forest City, NC facility. You will lead process improvements, support DFMEA reviews, and collaborate with quality to certify processes.

This role requires strong project organization and exceptional communication to drive safe, quality, and productive outcomes. Five plus years in plastic process engineering with extrusion and injection molding experience is preferred.

Qualifications

• 5+ years of demonstrable plastic process engineering experience (RJG training a plus).
• Experience with plastics manufacturing, pipe and profile extrusion, polypropylene, and polyethylene.
• Hands-on experience in plastic extrusion and injection molding processes.
• Mechanical knowledge of process set-up and molding equipment, including robotics, injection machines, molds, and heat control systems.
• Knowledge of analysis tools: Six Sigma, Control Charting, Root Cause Analysis, Fishbone Analysis, Pareto Analysis, SPC.
• Ability to read and interpret technical 2D and 3D drawings.
• Proven analytical and problem-solving skills on shop floor with varying equipment.

Responsibilities

• Work safely in a manufacturing environment following all plant safety procedures.
• Assist in part design reviews with emphasis on DFMEA and good manufacturing practices.
• Inspect, sample, and modify new tooling to create a stable process ready for production.
• Assist the engineering team in transitioning new projects to manufacturing.
• Implement continuous improvement projects focused on process, part quality, and efficiency, ensuring a solid ROI.
• Provide hands-on support to the production floor, including troubleshooting molds, repairs, PM, and refurbishments.
• Communicate effectively with internal and external customers in a professional manner.
• Implement visual controls and standard work in the department.
• Work with plant leadership to improve safety initiatives.
• Be willing to work extended hours as needed, including domestic and international travel.

Skills

Plastic extrusion

Injection molding

Problem solving

Communication skills

Tools

RJG training

Six Sigma

Control charts (SPC)

Root cause analysis

Job description

Sonoco is seeking a hands-on Plastics Process Engineer to qualify extrusion tools and develop manufacturing standards at our Forest City, NC facility. You will lead process improvements, support DFMEA reviews, and collaborate with quality to certify processes.

This role requires strong project organization and exceptional communication to drive safe, quality, and productive outcomes. Five plus years in plastic process engineering with extrusion and injection molding experience is preferred.