Sr. Process Engineer

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

Benefits offered by this job

Health care options

Dental coverage

401(k) plan

Paid time off

Employee stock grant

Job summary

Ingersoll Rand is seeking a Senior Process Engineer in Vernon Hills, IL, to lead the development and optimization of molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR). You will play a critical role in driving manufacturing performance through process capability improvements, cycle time optimization, and troubleshooting.

The ideal candidate should have over 5 years of relevant experience, a Bachelor's degree in engineering, and a strong grasp of molding techniques and statistical tools. The position offers a competitive salary and a comprehensive benefits package.

Qualifications

• 5+ years' experience in silicone and/or rubber molding.
• Strong understanding of cure cycles and material behavior.
• Experience using DOE, SPC, and statistical tools.

Responsibilities

• Develop and optimize LSR and HCR molding processes.
• Provide technical support for molding issues.
• Drive continuous improvement projects.

Skills

LSR injection molding

HCR molding

Process optimization

Troubleshooting

Lean methodologies

Statistical process control

Education

Bachelor's degree in Engineering

Tools

SolidWorks

Job description

Job Title

Sr. Process Engineer

Location

Lincolnshire, IL

Job Overview

The Process Engineer is responsible for the development, optimization and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The Process Engineer plays a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues and ensuring stable manufacturing performance across all molding work centers. The Process Engineer collaborates closely with the Tooling, Production, Quality, NPI and Maintenance teams to ensure successful product launches, consistent quality and efficient manufacturing processes.

Process Development & Optimization

• Develop, validate and optimize molding processes for LSR injection molding, HCR injection, compression and transfer molding, 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 optimize process capability (Cp/Cpk) and reduce variation.
• Establish and maintain standardized process parameter sheets, recipes and work instructions.

Troubleshooting & Technical Support

• Provide daily technical support to address molding issues such as flash, short shots, cure variations, knit lines and voids, sticking and ejection problems, inconsistent shrink, durometer and dimensional stability.
• Lead structured root cause analysis (5 why, 8D, fishbone) and implement robust corrective and preventative actions.
• Train operators and technicians in molding best practices and process discipline.

Tooling & Equipment Interaction

• Partner with Tooling Engineer on gate/vent design for silicone and rubber molds, cold runner or valve‑gate LSR systems, mold thermal management and vent maintenance, mold qualification and production readiness.
• Support maintenance to ensure equipment (presses, injection units, dosing systems, thermolators) operate within validated performance parameters.
• Provide feedback to improve mold robustness, reduce tool wear and minimize flash related issues.

Continuous Improvement

• Drive improvements in cycle time optimization, scrap and rework reduction, OEE (availability, performance and quality), material usage and yield optimization.
• Participate in LEAN, Kaizen, 5S and efficiency projects.
• Use SPC, data analytics and process monitoring to identify and address instability.

Cross-Functional Collaboration

• Work with NPI Engineering on feasibility reviews, new mold trials and qualification, launch readiness and transfer to production.
• Support quoting/estimating with cycle time projections, material behavior expectations, cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks and improvement projects.

General Accountability

• Cooperation and professional conduct with coworkers, staff, and managers.
• Demonstrate Flexan corporate values: Quality, Accountability, Respect, Innovation, Integrity, Open & honest communication, teamwork, customer focus.

Requirements

• Bachelor's degree in an Engineering discipline (Mechanical, Manufacturing, Materials, Plastics, Polymer).
• 5+ years' direct experience in silicone and/or rubber molding, with strong understanding of LSR injection, HCR molding, compression and transfer molding, cure cycles, post‑cure and material behavior.
• Tool design elements (cavitation, gating, venting, steel types).
• Experience using DOE, SPC and statistical tools for process improvement.
• Strong ability to interpret engineering drawings, GD&T, CAD models, customer and 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.li>
• 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 would be beneficial.

Travel & Work Arrangements / Requirements

Onsite.

Compensation

The pay range for this role is $100,000 – $125,000.

Benefits

Ingersoll Rand offers a comprehensive benefits package including health care options (medical, prescription), dental and vision coverage, wellness programs, life insurance, 401(k) plan, paid time off, and employee stock grant.

Equal Opportunity Employer

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.