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Senior Injection Molding Process Engineer Jobs in Milwaukee, WI

Milwaukee Tool

Senior Process Engineer

Mukwonago, WI · On-site

$102K - $132K/yr

As a Senior Process Engineer , you will serve as the technical specialist for plastic injection molding - leading process development, optimization, and long-term sustainment. You will drive ...

htna

Principal Process Engineer

Milwaukee, WI

The role focuses on optimizing the injection molding process by leveraging the latest cutting-edge ... Recognize opportunities for improvement in systems or processes, work with the Senior Process ...

MGS Mfg. Group, Inc

Process Engineer

Richfield, WI

As a Process Engineer at MGS, you will be responsible for the upkeep of equipment and processes to ... Devises and recommends new or modified components of plastic injection molding machinery.

MGS Mfg. Group, Inc

Process Engineer

Richfield, WI

As a Process Engineer at MGS, you will be responsible for the upkeep of equipment and processes to ... Devises and recommends new or modified components of plastic injection molding machinery.

MGS Mfg. Group, Inc

Process Engineer

Richfield, WI · On-site

As a Process Engineer at MGS, you will be responsible for the upkeep of equipment and processes to ... Devises and recommends new or modified components of plastic injection molding machinery.

HotRun Inc.

Process Technician

Milwaukee, WI · On-site

$30 - $42/hr

Senior Process Technician (Injection Molding) Sector: Tier 1 Automotive & High-Precision ... Work closely with Engineering during mold trials (sampling) to define the process window and ...

HotRun Inc.

Process Technician

Milwaukee, WI · On-site

Senior Process Technician (Injection Molding) Sector: Tier 1 Automotive & High-Precision ... Work closely with Engineering during mold trials (sampling) to define the process window and ...

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Senior Injection Molding Process Engineer information

See Milwaukee, WI salary details

$73.9K

$119.3K

$168K

How much do senior injection molding process engineer jobs pay per year?

As of Aug 7, 2026, the average yearly pay for senior injection molding process engineer in Milwaukee, WI is $119,329.00, according to ZipRecruiter salary data. Most workers in this role earn between $102,500.00 and $132,500.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive as a senior injection molding process engineer?

To thrive as a Senior Injection Molding Process Engineer, you need a deep understanding of polymer science, mold design, process optimization, and typically a degree in engineering or a related field. Expertise with CAD software, process simulation tools, and familiarity with quality systems like ISO 9001 are commonly required, along with certifications such as RJG or Six Sigma. Strong analytical thinking, problem-solving abilities, and effective communication are essential soft skills for collaborating with cross-functional teams and troubleshooting production issues. These skills ensure efficient production, high-quality output, and continuous improvement in complex manufacturing environments.

What does a senior injection molding process engineer do?

A Senior Injection Molding Process Engineer is responsible for designing, optimizing, and troubleshooting the injection molding process used to manufacture plastic parts. They oversee process improvements, ensure product quality, and collaborate with cross-functional teams to meet production goals. Additionally, they may develop and implement new molding technologies, train staff, and support maintenance of equipment to ensure efficient and reliable operations.

What is the difference between Senior Injection Molding Process Engineer vs Injection Molding Technician?

AspectSenior Injection Molding Process EngineerInjection Molding Technician
CredentialsBachelor's degree in engineering or related field, certifications in process optimizationTechnical diploma or associate degree, on-the-job training
Work EnvironmentDesigning processes, analyzing data, improving production efficiencyOperating machinery, performing setup and maintenance
ResponsibilitiesProcess development, troubleshooting, process validationMachine operation, quality checks, routine maintenance

The Senior Injection Molding Process Engineer focuses on process design, optimization, and troubleshooting, requiring higher-level technical skills and education. In contrast, the Injection Molding Technician handles daily machine operation and maintenance tasks. Both roles are essential in the manufacturing environment but differ in scope and responsibilities.

What are the common challenges faced by senior injection molding process engineers when introducing a new mold into production?

Senior Injection Molding Process Engineers often encounter challenges such as optimizing process parameters for new molds, ensuring part quality meets specifications, and troubleshooting issues like warpage or incomplete filling. Collaboration with design, tooling, and quality teams is essential to address these challenges and implement effective solutions quickly. Additionally, balancing production efficiency with consistent quality requires careful monitoring and adjustment during the initial production runs.
What are the most commonly searched types of Injection Molding Process Engineer jobs in Milwaukee, WI? The most popular types of Injection Molding Process Engineer jobs in Milwaukee, WI are:
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What cities near Milwaukee, WI are hiring for Senior Injection Molding Process Engineer jobs? Cities near Milwaukee, WI with the most Senior Injection Molding Process Engineer job openings:
Senior Injection Molding Process Engineer jobs near you
Infographic showing various Senior Injection Molding Process Engineer job openings in Milwaukee, WI as of August 2026, with employment types broken down into 100% Full Time. Highlights an 100% In-person job distribution, with an average salary of $119,329 per year, or $57.4 per hour.

Senior Process Engineer

Milwaukee Tool

Mukwonago, WI • On-site

$102K - $132K/yr

Full-time

Re-posted 20 days ago

Job description

Job Description:

WE CREATE EMPOWERED LEADERS!
At Milwaukee Tool, we believe our people and our culture are the driving forces behind our success.

As a Senior Process Engineer, you will serve as the technical specialist for plastic injection molding - leading process development, optimization, and long-term sustainment. You will drive manufacturing excellence through data-driven decision-making, advanced process control, and continuous improvement.

Key Responsibilities:

  • Develop, optimize, and sustain injection molding processes using scientific molding principles to achieve quality, delivery, and cost targets.

  • Define and validate robust process windows, control strategies, and safeguards using DOE, Cp/Cpk, and statistical methods.

  • Support tooling lifecycle activities, including design reviews, build validations (T0/T1/Tn), and continuous process/tooling improvements.

  • Drive root cause analysis and corrective/preventive actions for molding-related defects, leveraging data to eliminate systemic issues.

  • Partner cross-functionally with design, tooling, quality, and operations to ensure manufacturability and performance targets are met.

  • Identify trends through process and quality data to drive continuous improvement and defect reduction initiatives.

  • Create and maintain standardized process documentation (SOPs, control plans) to ensure repeatability and scalability.

  • Provide technical leadership, training, and support to manufacturing teams to strengthen process capability and execution.

Education and Experience Requirements

  • BS in Plastics Engineering Technology or equivalent

  • 5+ years of hands-on thermoplastics processing experience.

  • RJG Master Molder I/II strongly preferred.

  • Demonstrated expertise in scientific molding, process validation, and process troubleshooting.

  • Strong understanding of mold design, tooling principles, material data, molding machines, auxiliaries, and process monitoring tools.

  • Robotic programming and troubleshooting required.

  • Strong problem-solving skills (A3 / 5 Why / 8D) and attention to detail are essential.

  • Preferred Proficiency in CAD/CAE

  • Great to have Six Sigma Yellow or Green belt.

Milwaukee Tool is an equal opportunity employer.

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