Senior Molding Engineer

Position Summary

The Sr. Molding Engineer will lead and coordinate the technical phases of process development in conjunction with manufacturing and new product development initiatives. 

Lead the identification and development of next-generation processes related to molding plastics processing.

Lead inputs to process design, develop, and identify new manufacturing methods and designs. Conduct science-based testing to identify best practices and optimize process parameters to establish the quality and dimensional stability of molded components while developing a robust validation package for the molding process. 

Principal Responsibilities

•    Make high-level technical presentations to SBU leadership and executive management to convey project status and technical feasibility of injection molding and plastics processing projects.
•    Engineering lead for all aspects of molding process development, including the involvement in DFM, prototyping, testing (measurement), process characterization, process development history documentation, and design transfer into manufacturing with a robust validation package.
•    Provide guidance, input, and support to redesign existing processes to improve quality, utilize automated production techniques, optimize process capabilities, and produce better products more cost-effectively.
•    Independently plan and technically lead tasks on multiple projects, utilizing project plans and schedules to track and communicate developments from prototype design through pilot production. Formulate decisions to facilitate project advancement independently of a supervisor.
•    Independently interface with product development and manufacturing to understand product requirements and establish design criteria for developing manufacturing processes.
•    Provide input on material selection for new molded components based on knowledge of commonly used materials in medical device manufacturing. 
•    Conduct DOEs and establish statistically based recommendations for the molding process utilizing tools such as Minitab. 
•    Use computer-aided engineering tools such as Moldflow, SolidWorks, etc, to create and solidify tooling and mold specifications.
•    Identify and create new process concepts. Design and validate processes and components using engineering principles and adhering to the design control process as appropriate.
•    Participate in design and technical phase reviews focusing on design for manufacturing elements.
•    Interface with vendors to obtain quotations, purchase components and equipment, and debug problems supporting process development.
•    Investigate or direct the investigation of product complaints to determine the cause and implement corrective action.
•    Provide training and documentation to production to ensure a smooth design transfer.
•    Support, maintain, and upgrade production processes, including molding, insert molding, and assembly. Lead the identification, development, and introduction of new processes and control methods into manufacturing, as well as the creation of best practices in product development.
•    Develop robust and capable processes ("Scientific Molding" Philosophies) for new and existing manufacturing products. Document, validate, and determine standards for them.
•    Prepares or reviews documentation with high accuracy, completeness, and effectiveness using engineering tools and templates where available (i.e., validation documents, specifications, manufacturing procedures, EGOs, and technical reports or analysis summaries).

Principal Responsibilities, cont.

•    Applies and leads DMAIC- Six Sigma approaches to solve issues and reduce variation in all manufacturing and business processes.
•    Consult with Teleflex and non-Teleflex engineers, technicians, draftspeople, and manufacturing personnel regarding machine design, process/product design tooling/fixturing, and production problems.
•    Coordinate or participate as technical lead for manufacturing transfer of new products, including manufacturing trials, or existing products.
•    Mentor technical personnel in using current best practices and advanced initiatives in injection molding.
•    Visit other Teleflex facilities as required to resolve manufacturing or new product development problems.
•    Perform as the recognized subject matter expert for plastics processing by directing and consulting other employees seeking related knowledge.
•    Provide Technical support for all manufacturing transfers of plastics processing operations across global operations.
•    Adhere to and ensure the compliance of Teleflex's Code of Ethics, all Company policies, rules, procedures, and housekeeping standards.

Education / Experience Requirements

•    BS in Engineering, or equivalent, MS Degree preferred (Mechanical and/or Plastics Engineering)
•    5-7 years of experience in process support and development; minimum of 3 years of previous experience in related field (e.g., medical device manufacturing & assembly, plastic injection molding, plastics, automation).
•    Must have medical device manufacturing experience, including transferring products from design to manufacturing.
•    Must have demonstrated ability and experience to balance and multitask multiple engineering projects and programs supporting internal customers.
•    Expert understanding of polymer materials properties and the practical application of these principles in establishing robust manufacturing processes, troubleshooting, and consulting with R&D on material selection.
•    Must have working knowledge of Microsoft Office, Minitab, SolidWorks & Mold Simulation Analysis
•    Must apply engineering concepts, original thinking, cause and effect, and ingenuity to solve problems.
•    Must be a skilled statistical practitioner and apply statistical analysis to determine process capabilities, compare populations via hypothesis testing, utilize process control charting, and use the output of these analyses to improve operations. Six Sigma certification is highly desirable.
•    Knowledge and experience designing and performing Design of Experiments (DOE) is desirable.
•    Knowledge of two-shot molding practices and applications. 
•    RJG Master Molder II certification or equivalent is preferred.
•    Knowledge and application of common measuring techniques and tools such as OQP, Keyence, or equivalent
•    Able to travel domestically and internationally (up to 25%)

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