Sr. Process Engineer

Ingersoll Rand; Mundelein (IL); On-site; USD 100,000 - 125,000; Full time

Benefits offered by this job

Health care options (medical, prescription, dental, vision)

401(k) plan

Paid time off

Job summary

Ingersoll Rand is seeking a Sr. Process Engineer in Mundelein, IL, responsible for optimizing molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR). The role includes troubleshooting, training, and continuous improvement efforts.

Candidates should possess a Bachelor's degree in a related engineering field and have over 5 years of practical molding experience. A range of benefits is offered, including health care options and a 401(k) plan.

Qualifications

• 5+ years of direct experience in silicone and/or rubber molding.
• Strong knowledge of LSR injection, HCR molding, compression and transfer molding.
• Ability to interpret engineering drawings and specifications.

Responsibilities

• Develop, validate and optimize molding processes for LSR injection molding.
• Troubleshoot production issues and ensure stable manufacturing performance.
• Train operators and technicians in molding best practices.

Skills

LSR injection molding

HCR molding

Statistical Process Control (SPC)

Root-cause analysis

Education

Bachelor's degree in Mechanical, Manufacturing, Materials, Plastics, Polymer or related engineering field

Tools

SolidWorks

3D modelling software

Job description

Sr. Process Engineer – Lincolnshire, IL

Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.

Job Overview

The Process Engineer is responsible for the development, optimization and sustained operation of robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The role drives process capability, optimizes cycle times, reduces scrap, troubleshoots production issues, and ensures stable manufacturing performance across all molding work centers.

Responsibilities

• Develop, validate and optimize molding processes for LSR injection molding.
• Optimize HCR injection, compression and transfer molding.
• Implement multi-cavity, family molds and multi-shot configurations.
• Apply scientific molding techniques to establish injection/fill profiles, pack/hold strategies, cure and thermal control profiles, venting and flash prevention parameters.
• Perform process determination and DOE studies to improve capability (Cp/Cpk) and reduce variation.
• Maintain standardized process parameter sheets, recipes and work instructions.
• Provide daily technical support for molding issues such as flash, short shots, cure variations, knit lines, voids, sticking, ejection problems, inconsistent shrink, durometer and dimensional stability.
• Lead structured root‑cause analysis (5‑why, 8‑D, fishbone) and implement corrective and preventative actions.
• Train operators and technicians in molding best practices and process discipline.
• Partner with Tooling Engineer on gate/vent design, cold runner or valve‑gate LSR systems, mold thermal management and vent maintenance, mold qualification and production readiness.
• Support maintenance to ensure equipment operates within validated performance parameters and provide feedback to improve mold robustness, reduce tool wear and minimize flash issues.
• Drive continuous improvement in cycle time, scrap, rework, OEE, material usage and yield.
• Participate in LEAN, Kaizen, 5S and efficiency projects and use SPC, data analytics and process monitoring to address instability.
• Collaborate with NPI Engineering on feasibility reviews, new mold trials, qualification, launch readiness and transfer to production.
• Support Quoting/Estimating with cycle time projections, material behavior expectations and cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks and improvement projects.
• Demonstrate cooperation, accountability, communication, integrity, teamwork, customer focus and respect with coworkers, staff and management.

Requirements

• Bachelor's degree in Mechanical, Manufacturing, Materials, Plastics, Polymer or related engineering field.
• 5+ years of direct experience in silicone and/or rubber molding.
• Strong knowledge of LSR injection, HCR molding, compression and transfer molding, cure cycles, post‑cure and material behavior.
• Experience with tool design elements (cavitation, gating, venting, steel types).
• Proficiency in DOE, SPC and statistical tools for process improvement.
• Ability to interpret engineering drawings, GD&T, CAD models and customer/regulatory specifications.
• Demonstrated success in troubleshooting complex molding issues.

Preferences

• Experience with SolidWorks or other 3D modelling software.
• Experience with mold flow analysis or ability to interpret results.
• Background in medical, automotive, aerospace or industrial silicone components.
• Experience supporting APQP, PPAP and customer audits.
• Experience with automation, vision inspection and deflashing/trimming technologies.
• Background with adhesion/bonding techniques, multi‑shot molding and overmolding.
• RJG/Paulson certification or silicone‑specific molding training.
• Familiarity with ISO13485 and clean room procedures.

Travel & Work Arrangements/Requirements

Onsite.

Pay

Salary range: $100,000 – $125,000.

Benefits

Health care options (medical, prescription, dental, vision), wellness programs, life insurance, 401(k) plan, paid time off, and employee stock grant. Ingersoll Rand is committed to a comprehensive benefits package that supports health, well‑being and professional growth.

Equal Employment Opportunity Statement

Ingersoll Rand is committed to achieving workforce diversity reflective of our communities. We are an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.