Process Engineer, Manufacturing Engineering (Plastic Injection Molding)

As a Process Engineer in Manufacturing Engineering, Plastic Injection Molding at SpaceX, you will primarily focus on developing and qualifying injection molding processes, maintaining production uptime of molding machines, conducting materials analyses, and training production staff. Your role will include auditing manufacturing processes for inefficiencies and leading design of experiments to ensure stable operations.

To apply for the Process Engineer position at SpaceX, candidates should hold a Bachelor’s degree in mechanical engineering, materials engineering, or a related engineering discipline. A minimum of 1+ years of injection molding experience in a production environment is required, while a Master's degree or PhD and additional experience are preferred.

As a Process Engineer at SpaceX, you will work on groundbreaking projects involved in the production of components for the Starlink product line. You will develop new manufacturing methods, engage in process optimization, and contribute to projects that aim to revolutionize global satellite internet connectivity.

Beneficial skills for a Process Engineer at SpaceX include experience troubleshooting and programming robots in molding cells, mechanical/electrical maintenance knowledge, and the ability to interpret geometrical tolerances on part drawings. Familiarity with PLCs, sensors, and injection molding automation will also provide you with an edge.

The work culture at SpaceX is fast-paced, innovative, and encourages collaboration among engineers. As a Process Engineer, you will be part of a team focused on advanced manufacturing techniques. There is an emphasis on problem-solving and continuous improvement, creating an engaging and stimulating environment.

Documentation is critical in the injection molding process as it helps ensure consistency and quality of manufacturing. It allows for tracking process settings, improvements, and deviations, which are essential for quality control and compliance. As a Process Engineer, you'll ensure that all operations are properly documented to facilitate training and process audits.

When troubleshooting a molding machine, I start with a systematic evaluation of the process parameters and recent changes made, checking machine settings, sensors, and electrical components. It's important to gather data on the issues being encountered. I believe in applying a root-cause analysis approach, using the information to pinpoint the issue and implement a solution.

In my previous role, I utilized design of experiments to optimize a plastic injection molding process. I identified critical factors affecting quality and utilized statistical analysis to determine the best settings and material combinations to achieve optimal outcomes in terms of consistency and quality, ensuring a smooth handover to production.

To improve manufacturing process efficiency, I employ techniques such as process audits, value stream mapping, and the implementation of automation. Constantly assessing workflow and machine performance allows me to identify bottlenecks and areas for improvement, which leads to better productivity and reduced waste.

I approach training production staff by creating detailed training manuals and conducting hands-on sessions where team members can practice using the equipment. I ensure that training is engaging, allowing questions and feedback to tailor the sessions to the team’s needs. Continuous support after training is also vital for success.

Materials analysis is essential in the injection molding process as it helps determine the most suitable polymers for specific applications. It ensures that the materials used meet the required specifications for durability, flexibility, and performance, leading to high-quality end-products.

In a previous project, we faced unexpected quality issues with a product due to material inconsistencies. I led the investigation, coordinating with suppliers and conducting comprehensive tests. Through this, we identified the root cause and established strict quality checks that improved our production stability significantly.

I have implemented several safety improvements, such as updated safety protocols for machine operation, better ergonomics training, and emergency shutdown procedures. By fostering a culture of safety and encouraging feedback from employees, we were able to significantly reduce incidents in the manufacturing environment.

In a busy manufacturing setting, I prioritize tasks based on urgency and impact on production. I utilize tools like Kanban boards to visually manage workflow and adjust priorities as needed, ensuring that all teams are in alignment and objectives are met without compromising timelines or quality.

My passion for injection molding and aerospace manufacturing stems from the dynamic nature of the field and its real-world impact. Being a part of projects that contribute to space exploration and technological advancements drives my enthusiasm, as I love solving complex problems and pushing the boundaries of what’s possible.