Plastic Process Engineer

Job Title: Plastic Process Engineer

Department: Blow Molding

Reports To: Chief Engineer

Location: Culpeper, VA

Job Type: Direct Hire

Salary: $95,000

Job Summary: Qualdoc is seeking a skilled Plastic Process Engineer to develop, implement, monitor, and maintain efficient manufacturing processes (injection molding, blow molding, and extrusion). The ideal candidate will be responsible for designing and implementing system and equipment procedures used in our manufacturing facilities. They will also evaluate technical and economic factors, as well as recommend engineering and manufacturing action plans to attain effective processes with better performance. The ideal candidate must be a proactive solutions provider, capable of identifying challenges and delivering effective, innovative solutions to meet business needs.

• Be a visible example of safety leadership on the shop floor.
• Must develop expertise of all critical processes, equipment, and inputs to develop control plans for the same.
• Oversee existing process and workflows, conduct necessary research to develop existing process into new and improved process for manufacturing.
• Analyze product or equipment specifications and performance requirements to determine processes which can be achieved by existing manufacturing or processing facilities and methods.
• Review training documents and conduct necessary cross-training on operating procedures.
• Conduct testing and monitor the process performance throughout production and make necessary process improvements.
• Review BOMs and make necessary changes based on cycle time study and process flow and assist R&D with developing new BOMs (Bill of Materials) for new product development.
• Perform FAT (First Article Testing) for new injection molding, pipe extrusion and blow molding tooling.
• Assist operation and product development team with launching new products.
• Plan and develop experimental test program. Analyze test data and report to determine if process results meet functional and performance specifications.
• Track metrics to discover areas for continuous improvement and monitor upgrades. Based on that, communicate necessary findings and proposals to upper management.
• Provide technical information concerning manufacturing or processing techniques, materials, properties and process advantages and limitations which affect long range plant and product engineering planning.
• Assist with determining feasibility of new plant equipment or modifying existing facilities considering costs, available space, time limitations, company planning and other technical and economic factors. Confer with engineering and operation personnel and submit process modification recommendations as required. Based on that, direct and coordinate manufacturing or building equipment or system.
• Consult CI/Process/Quality engineer for developing quality standards generation and implementation to reduce scrap either by improving or modifying the process.
• Implement CI techniques like 6S, Lean Manufacturing, PDCA, 5Why’s, 3M’s and more by consulting CI/Process/Quality Engineer. Also help in implementing and performing Kaizen events/training.
• Perform/Review daily FAI (First Article Inspection) on production run.
• Maintain daily scrap report and derive a plan to improve product quality and reduce scrap.
• Apply Lean Manufacturing and Six Sigma tools and methodologies in the implementation of manufacturing excellence initiatives.
• Have ability to facilitate improvement team meetings.
• Implement six sigma projects that focus on reducing process and product variation.
• Train, coach and motivate personnel in the understanding and adoption of new principles and techniques.
• Troubleshoot process issues with an eye toward systematic improvements.
• Assist in the root cause analysis of Quality Complaints and the development of action plans to prevent reoccurrence.
• Drive Lean Manufacturing initiatives to eliminate waste of value streams.
• Contribute to departmental efforts by accomplishing related tasks as needed.

• B.S. in Engineering or college degree with 5+ years working in plastic industry (injection molding, blow molding, or extrusion) required.
• 3+ years of experience in plastic industry (injection molding, blow molding, or extrusion) required.
• Experience working with all three-manufacturing processes: injection molding, blow molding, and extrusion is a plus.
• Frequent travel to and from multiple plants is required.
• Experience working with an ERP system is required.
• Experience working with material like ABS and Poly propylene is plus.
• Proven track record of problem solving in a metals manufacturing industry preferred.

Physical Requirements: This position may require frequent bending, lifting, and moving objects weighing up to 50 pounds. Employees should be able to perform this duty with or without reasonable accommodations.

Subject to a pre-employment drug test and/or background check.