Process Engineer

2 weeks ago

Sterling Heights, United States Coplas Inc. Full time
Job DescriptionJob DescriptionSummary of Position:
  • Reporting to the Molding Manager, the Process Engineer is responsible for supporting the product development process as an advisor, driving technical solutions to support manufacturing injection mold designs and improve standards for part design. Responsibilities include from design concept, Mold Flow, and processing through to the manufacturing process to meet the established quality, production and safety standards. They will be responsible for ensuring the ongoing adherence to the policies and procedures outlined in the ISO9001:2015 AND IATF 16949 Quality System and encouraging continuous improvement wherever possible.

details of Principal Duties, Activities and Responsibilities

  • Responsible for the daily activities with the technical aspects of the molding processes to ensure that a controlled stable process is being run and that overall safety practices are being followed.
  • Ensure that proper start-up, shut-down, and troubleshooting procedures are being followed.
  • Support mold maker with mold tool troubleshooting and perform program troubleshooting to injection mold equipment including robotics and end of arm tooling
  • Preform mold preventative maintenance such as visual issues, component wear, clean and lube, etc.
  • Ensure all processes are running to baseline and that any changes are properly evaluated and documented with the appropriate change form.
  • Investigate new technologies and determine their viability to our products (conformal cooling, pulse cooling, cavity pressure sensors, electric servo, valve gate systems, etc.)
  • Provide technical leadership and mentorship to process technicians, operators and other molding personnel.
  • Assists in the development of injection mold set-up/processing sheets, procedures and instructions for Prototype and Production sampling.
  • Assure product and process quality by setting process variables; establishing standards; and confirming all sampling processes. Develop and maintain process documentation.
  • In-depth knowledge of Scientific Moulding Techniques (Gate Seal Study, Cavity Balance, Rheology Study, etc.) and Decoupled Moulding Techniques.
  • Experience with analyzing Moldflow results to assure optimum part processing, cooling efficiency and quality. Determine that all Moldflow results are within limits for:
    • Cavity fill pressure and balance.
    • Part, melt and tool steel temperatures.
    • Shear rate and shear stresses.
    • Sink marks and weld/meld lines.
    • Cycle time.
    • Warp and deflections.
  • Ability to transfer moulding processes to different machines using engineering calculations to determine the machines suitability for production of the product.
  • Extensive experience troubleshooting moulding processes, machines and auxiliary equipment (dryers, water temperature controllers, hot runner systems, gating and valve gates)
  • Supports new product launches utilizing APQP process, including support for new capital requests.
  • Ability to assist in the quoting process for new parts such as cycle time estimation and determine suitability of existing equipment.
  • Provides technical support to plant quality with participation and engineering analysis of quality rejections for existing product.
  • Support continuous improvement by providing technical support to plant manufacturing by participating in lean and cost savings projects. Providing longer term processing solutions that will reduce costs by way of improved scrap rates and optimized efficiency.
  • Understands and performs daily job duties in a manner which supports the plant's goals and quality objectives.
  • Promotes an atmosphere conscious of environmental, safety and health practices, ensuring compliance with all quality and safety protocols.
  • Provide support in a supervisor role at times to process technicians, operators and other molding personnel
  • Travel to customers or other facilities as needed
  • Promote continuous improvement in all areas.
  • Other duties as assigned
  • ISO9001:2015 AND IATF 16949 duties as required

QUALIFICATIONS

Education Required

Minimum Secondary School Diploma

Applicable Post-secondary Education or Technical Diploma in a related field is an asset

Core Competencies

Paulson Training

Mechanically inclined

Effective communication skills, verbal, and written.

Computer skills

Understanding of injection mold processing using a wide variety of commodity and engineering grade plastics.

Ability to evaluate molding and tooling problems for best solutions.

Ability to manage complex assignment priorities.

Experience Required

Minimum of 5 years in a hands on technical role in Injection Mold environment.

Experience in a leadership role (Supervisor or Management) preferred

Experience with injection mold equipment and tooling

Automotive experience is an asset


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