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Senior Molding Engineer

4 months ago

West Valley City, United States Flexan Full time

Utilizing Scientific Molding tools and programs the Sr. Molding Engineer will develop the most cost effective and robust processes for all injection molded products. Based on data generated from molding studies and designs of experiments, will ensure all molds are operating at optimum output and efficiency meeting all quality requirements and generating the most cost savings possible. Designs processes for all new molds. Supports production manufacturing with any processing or mold issues with existing molds and mitigates all issues being experienced. This position is 90 percent of the time spent on the molding floor.

KEY ROLE AND RESPONSIBILITIES:

  • Promote Safety First in all Molding areas, equipment, processes, and procedures.
  • Ensures all molding machinery is operating as it was designed to operate.
  • Working with maintenance staff, ensures all PMs for machinery and injection molds are being followed and completed as timelines dictate.
  • Develops process for each new mold based on scientific studies. Maintains all documentation in shared file for every mold and process. Includes, part and mold drawings and or models, process data sheets, scientific studies data sheets, CPk data sheets and centered process information. All sampling plans and process studies. All Quality information relating to tooling, process and part approval. All validation processes and data. All product requirements of operator, packaging, step by step work instructions for production. All ancillary equipment settings. Robot, dryer, conveyor system, hot runner, water temperature controller, resin technical data sheets, process data sheet with window built around set points for productions use.
  • Brings new products through first article inspection and through QA and customer requirements needed for production of product meeting required timeline expectations.
  • Evaluates all processes and molds and recommends improved changes to existing molds, machinery, secondary equipment or other processing technologies on a regular basis for cost savings.
  • Works with trains and develops setup personnel and process technicians or trainees.
  • Carries out any tooling/resin trials. Completes in a timely manner and within timeline requirement.
  • Identifies any production or quality issues and establishes root cause/corrective actions needed and develops plan of action to address these.
  • Performs routine audits of existing molding processes to assure proper systems performance and maintenance.
  • Reviews all SPC molding data and develops critical in process alarms on process monitoring screens and equipment to actively segregate parts.
  • Actively supports Flexan commitment to quality and all quality objectives. Puts an emphasis on continuous improvement and lean manufacturing principles.
  • Supports Engineering team with roll out of new tooling ideas and plans. Attends DFM reviews and provides professional input to team reviews.
  • Investigate and recommend new technologies and innovations in tooling, equipment and robotics to generate cost savings.
  • Responsible for driving cost savings and monitoring and reporting cost savings generated at year end.
  • Performs additional duties and projects as assigned.
  • Demonstrates all the Flexan corporate values:
  • We have an engaging culture.
  • We embrace the rigor to be safety and quality driven in all that we do.
  • We embrace our choice to work here.
  • We operate with transparency, ethics, and integrity.
  • We consistently meet or exceed our expectations.
  • We encourage innovation.
  • We strive to deliver on time with best quality products at reasonable prices


Minimum Qualifications:
  • Two-year degree in a technical field (or equivalent) preferred.
  • Eight years of molding experience required. Molding experience in the Medical Device Industry preferred.
  • Master Molder 1 Certification is a minimum. Master molder 2 Certification is preferred. The expectation is that Master Molder 2 training is completed within 1 year of onboarding if currently a Master Molder 1.
  • Demonstrated ability to effective lead project and initiatives from start to finish.
  • Ability to effectively develop other molding team members on molding best practices and processes.
  • Excellent written communication and computer skills. Microsoft programs and SolidWorks preferred.
  • Sound understating of molding process validation and associated theory / tools.
  • Sound understanding of mold tooling Design for Manufacture (DFM).
  • Must be familiar with SPC and molding machine controllers.

Physical Demands
  • The employee is occasionally required to sit; climb or balance and stoop, kneel, crouch, or crawl.
  • The employee is frequently required to lift and/or move up to 25 pounds and occasionally lift and/or move up to 50 pounds.

Work Environment
  • The position requires work in a clean room environment and is expected to follow the guidelines and rules for working in the cleanroom. This includes following the gowning procedure, cleanroom manufacturing procedures, and Personal Protective Equipment (PPE).
  • While performing the duties of this Job, the employee is [frequently/occasionally] exposed to moving mechanical parts and operating molds.
This role requires the process engineer to be machine side and on the molding floor 90 percent of the day to bring the best results in process development and engineering