The Senior Process Technician is responsible for setting up, optimizing, and maintaining injection molding equipment to produce high-quality plastic components. This role serves as a technical leader on the production floor, mentoring junior technicians, troubleshooting process issues, and driving continuous improvement initiatives. The ideal candidate brings deep knowledge of injection molding processes, strong analytical skills, and a commitment to safety and quality.
Process Setup & Optimization
- Set up and start up injection molding machines (50–2,000+ ton) according to established process parameters and traveler documentation
- Develop, refine, and document robust molding processes, including fill studies, gate seal, and cushion analysis
- Optimize cycle times, shot weights, temperatures, pressures, and cooling profiles to meet quality and efficiency targets
- Perform mold validations (IQ/OQ/PQ) and first article inspections in coordination with quality and engineering teams
- Conduct Scientific Injection Molding (RJG or equivalent) studies to ensure process repeatability and capability
Troubleshooting & Quality
- Diagnose and resolve process-related defects including short shots, flash, sink marks, warpage, weld lines, splay, and dimensional non-conformance
- Collaborate with toolroom and engineering on mold repairs, preventive maintenance, and process improvements
- Monitor and interpret SPC data; respond to out-of-control conditions and initiate corrective actions
- Support root cause analysis (RCA) and lead 8D or A3 problem-solving efforts for recurring process issues
Leadership & Training
- Mentor and coach Process Technicians I & II on setup procedures, process fundamentals, and troubleshooting techniques
- Conduct on-the-job training and contribute to the development of work instructions and training materials
- Serve as the go-to technical resource during shift operations in the absence of Process Engineering staff
- Lead or participate in Kaizen events and lean manufacturing projects on the production floor
Documentation & Compliance
- Maintain accurate process sheets, change logs, and setup documentation in the MES/ERP system
- Ensure compliance with ISO 9001, IATF 16949, ISO 13485, or applicable quality management systems
- Adhere to all safety protocols including lockout/tagout (LOTO), PPE requirements, and machine guarding standards
- Participate in internal audits and support customer/third-party audits as needed
-