Resin Process Engineer Jobs in Milwaukee, WI (NOW HIRING)

Job Summary

The Advanced Molding Group Process Engineer is responsible for ensuring new injection molded parts and processes are optimized for production, generally using OEE (Overall Equipment Effectiveness) and the ability to establish a robust processing window as measures. This process engineer will use their knowledge, understanding, and experience to focus on higher-risk projects. These might be for parts, materials, or processes new to the organization or ones needing improvement.

Responsibilities include the ability to research and put into practice new and different materials or processes, and participation in corrective actions and continuous improvement efforts. This will be achieved while maintaining HellermannTyton's Quality and EHS&S certifications by supporting all corporate policies, procedures, work instructions, and required documentation.

Essential Functions:

• Work with others to get assigned projects into production with acceptable OEE and risk level.
• Provide guidance and mentoring to process engineers and technicians, as well as the project teams, to continuously improve all aspects affecting process engineering. Recommend learning opportunities for others.
• Collaborate with materials engineers, mold tooling engineers, and quality engineers to ensure systems and processes are optimized. Promote change where needed.
• Collaborate with materials engineers, mold tooling engineers, and quality engineers to ensure systems and processes are optimized. Promote change where needed.
• Equipment evaluation. Able to evaluate and, where applicable, recommend screw geometry, non-return valves, auxiliary equipment like dryers and blenders, etc.
• Problem solving. Can use and explain different root cause failure analysis techniques. Work with the materials engineer to recommend appropriate analytical methods and coordinate needed actions internally or with outside labs.
• Recommend hot runner setups
• Work with maintenance to establish proper preventive maintenance cycles on the presses and equipment.
• Assist the Director of Manufacturing and the Training Department to evaluate training needs for Process Engineers and Process Technicians.
• Can explain APQP, write and evaluate PFMEAs, and how all of it gets incorporated through Control Plans and level 3 PPAPs.
• Set up, run, and evaluate DOEs and make appropriate recommendations when needed.
• Assist the Director of Manufacturing in evaluating and making recommendations on key process-related equipment.
• Other duties as assigned.

Success in this role will require 

• Injection molding. Can set a mold and establish robust processes on a variety of injection molding machines across a variety of resins using scientific injection molding.
• Injection molding auxiliary equipment. Able to use/evaluate/recommend moisture analyzers, blenders, dryers, mold temperature control units, hot runner controllers, etc.
• Heat transfer. Can explain, calculate, and recommend mold cooling requirements.
• Can explain and figure out shear-induced flow groups and recommend appropriate course of action when fill-imbalance mitigation is needed, and how best to do that.
• Application of statistics. Able to interpret various statistical tools such as Cp, Cpk, and standard deviation.
• Calculate gate sizes using shear rate
• Explain mechanical mold design from a structural perspective. Able to properly recommend, specify, and interpret FEA analyses.
• Explain flow analyses. Able to properly recommend, specify, and interpret flow analyses.
• Can explain APQP Advanced Product Quality Planning. Can write PFMEAS. Has a working knowledge of DFMEAs, Control Plans, SPC, etc.
• Mold pressure and temperature sensing, EOAT, vision or other inspection systems. Work with process engineering, automation, IEs, maintenance, and other team members to implement appropriate strategies for maximizing OEE.
• Part inspection. Can read part drawings, preferably including GD&T, and perform basic measurements.
• Clear and concise written and verbal communication skills.
• Have and maintain a teachable point of view and an ability and aptitude to help others learn.
• Understands hygroscopic resin moisture absorption, desorption, and resin moisture effects on processing and part performance.
• Can explain and evaluate scientific injection molding practices.

What You’ll Bring

• Education. Bachelor’s degree in engineering, a related technical field, or experience with demonstrated progressive learning and responsibility.
• Minimum 5+ years of hands-on injection molding experience with a proven understanding of successful injection molding
• Proficiency with CAD software.
• Self-motivated. Results oriented
• Good technical writing skills.
• Good verbal and written communication skills.
• High mechanical aptitude.
• Software skills, including MS O365.
• Proven ability to work independently and manage multiple tasks in a fast-paced environment.
• Valid driver's license with an acceptable driving record, along with adequate automobile insurance.
• Capable and willing to travel 2 - 4 times per year.

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