Utilizing Scientific Molding tools and programs the Molding Engineer will develop the most cost effective and robust processes for all injection molded products. Based on data generated from molding studies, designs molding processes that ensure all molds are operating at optimum manufacturability, efficiency and with the best quality and most cost savings. Designs new mold processes for all new molds and supports production with any process or mold issues on existing molds and mitigates all issues being experienced. This position is 90 percent of the time spent on the molding floor.

KEY ROLE AND RESPONSIBILITIES:

• Promote Safety First in all Molding areas, equipment, processes, and procedures.

• Ensures all molding machinery is operating as it was designed to operate.

• Ensures all PMs for machinery and injection molds are being followed and completed as timelines dictate.

• Performs mold setups following setup data sheet information. Ensures all parameters are correctly input into machine controller.

• Maintains mold and machine spare parts inventory accurately and timely and shares inventory with team. Ensures we always have correct number of spare components on hand.

• Works collectively with molding technician and helps grow technician into a processor’s role.

• May mix resins on tumbler and ensure machines do not run out of material.

• Prepares all molds properly that need to be shipped to outside suppliers for repairs.

• Assists operators with training of products and following work instructions.

• Ensures all machinery is clean. Work areas are clean and safe.

• Is capable of working with hand tools and torquing of mold mounting bolts.

• Supports Sr Process Engineer in development of process for each new mold based on scientific studies. Maintains all documentation in shared file for every mold. Includes, part and mold drawings and or models, process data sheets, scientific studies data sheets, CPk data sheets and centered process information. All sampling plans and process studies. All Quality information relating to tooling, process and part approval. All validation processes and data. All product requirements of operator, packaging, step by step work instructions for production. All ancillary equipment settings. Robot, dryer, conveyor system, hot runner, water temperature controller, resin technical data sheets, process data sheet with window built around set points for productions use. Assists with any other Sr Process Engineers needs.

• Evaluates all processes and molds and recommends improved changes to existing molds, machinery, secondary equipment, or other processing technologies on a regular basis.

• Works with and trains setup personnel and process technicians or trainees.

• Carries out any tooling/resin trials. Completes in a timely manner and within timeline requirement.

• Identifies any production or quality issues and establishes root cause/corrective actions needed and develops plan of action to address these.

• Performs routine audits of existing molding processes to assure proper systems performance and maintenance.

• Actively supports Flexan commitment to quality and all quality objectives. Puts an emphasis on continuous improvement and lean manufacturing principles.

• Performs additional duties and projects as assigned.

• Demonstrates all the Flexan corporate values:

• We have an engaging culture.

• We embrace the rigor to be safety and quality driven in all that we do.

• We embrace our choice to work here.

• We operate with transparency, ethics, and integrity.

• We consistently meet or exceed our expectations.

• We encourage innovation.

• We strive to deliver on time, top quality at reasonable price

  Minimum Qualifications:

• Two-year degree in a technical field (or equivalent) a plus

• Fours years of molding experience required.  Molding experience in the Medical Device Industry preferred.

• Master Molder 1 Certification is preferred.  The expectation is that Master Molder 1 training is completed within 1 year of onboarding if certification is not currently held.

• Excellent written communication and computer skills. Microsoft programs and SolidWorks preferred.

• Sound understating of molding process validation and associated theory / tools.

• Sound understanding of mold tooling Design for Manufacture (DFM).

• Must be familiar with SPC and molding machine controllers.

  Physical Demands

   

• The employee is occasionally required to sit; climb or balance and stoop, kneel, crouch, or crawl.

• The employee is frequently required to lift and/or move up to 25 pounds and occasionally lift and/or move up to 50 pounds.

  Work Environment

   

• The position requires work in a clean room environment and is expected to follow the guidelines and rules for working in the cleanroom. This includes following the gowning procedure, cleanroom manufacturing procedures, and Personal Protective Equipment (PPE).

• While performing the duties of this Job, the employee is [frequently/occasionally] exposed to moving mechanical parts and operating molds.

• This role requires the process engineer to be machine side and on the molding floor 90 percent of the day to bring the best results in process development and engineering.

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