Senior Injection Molding Process Engineer Jobs (NOW HIRING)

At Sunstar Americas, Inc., we firmly believe that our people are the foundation of our success. We foster a collaborative, innovative, and agile culture that ensures we deliver high-quality, innovative products to consumers and oral care professionals. Our team-oriented approach encourages creative thinking and nurtures a positive work environment and productive relationships. With dedication, hard work, and a shared vision, we can continue to make SAI a leader in our industry.

Join us and become part of our global team, where together, we can achieve success and contribute to a better future.

Position Summary:

The primary responsibility of the Senior Process Technician is to serve as a floor-based technical leader and mentor, supporting Engineering-led initiatives by executing approved protocols, participating in Kaizen activities, and ensuring injection molding and vision-based camera inspection system processes are stable, capable, and compliant.

The secondary responsibility of this role is to provide hands-on technical leadership within the Molding Department as a scientific molding subject-matter expert, supporting validation execution, process optimization, and continuous improvement efforts.  Secondary responsibilities also include hands-on technical leadership for vision-based camera systems such as Keyence in Molding, Bristling and Packaging.

Engineering & Validation Support Essential Job Functions: ~ 60% 

• Execute machine, mold, and process validation activities (IQ/OQ/PQ) under the direction of Engineering and Quality. 

• Support validation documentation development as a technical SME, with primary responsibility focused on execution and data collection rather than   document authorship or approval

• Collect, analyze, and document molding process data during validation studies and engineering trials

• Execute approved protocol activities and clearly communicate results, deviations, and observations

• Support implementation of new equipment, molds, and process changes on the molding floor

• Support implementation and operation of new vision cameras in molding, bristling and packaging equipment.  Specifically: physical installation, vision        programming and integration.  Final integration would include corresponding with a responsible Controls Engineer to make final connections.

• Assist Engineering with continuous improvement initiatives through data-driven analysis and experimentation

• Ensure all validation and engineering support activities comply with internal procedures and applicable regulatory requirements

• Communicate technical findings effectively to Engineering, Quality, and Manufacturing teams 

Molding Department Support & Mentorship Essential Job Functions: ~40%

• Provide hands-on technical support to the Molding Department when not actively executing engineering or validation tasks

• Troubleshoot molding process issues related to quality, scrap, cycle time, and process stability

• Serve as a technical mentor to Process Technicians and Operators, reinforcing scientific injection molding principles and standard work

• Support Kaizen events and continuous improvement initiatives focused on safety, quality, delivery, and cost

• Assist with training efforts related to molding processes, validations, and best practices

• Act as a liaison between Engineering and Manufacturing to support effective communication and execution of process changes

• Help sustain process improvements through standardization and monitoring on the molding floor 

Education:

• High School Diploma or GED required

• Associate’s degree or Bachelor’s degree in Engineering (Mechanical, Manufacturing preferred but not required)

• RJG Master Molder I certification required

• RJG Master Molder II certification preferred but not required 

Knowledge/Experience:

• 5–10 years of injection molding experience, with the majority of time spent applying scientific injection molding principles

• Basic Vision system experience, understanding of how vision tools work and open to formal training.

• Hands-on experience in setting, optimizing, and troubleshooting injection molding processes using data-driven methodologies

• Experience supporting or executing machine, mold, and process validations in a regulated manufacturing environment (medical device preferred)

• Strong understanding of process capability, DOE fundamentals, and molding process robustness

• Proven ability to work effectively in a fast-paced, hands-on manufacturing environment

• Experience supporting cycle time reduction, scrap reduction, and continuous improvement initiatives

• Strong written and verbal communication skills with the ability to clearly document technical activities and results

• Ability to work cross-functionally with Engineering, Quality, and Manufacturing teams

• Strong organizational skills and ability to manage multiple priorities

• Demonstrated ability and willingness to mentor others and serve as a technical leader within the Molding Department 

What Makes Sunstar Special is:

• A business focused on health and wellness of people around the world
• High Quality Products
• Beautiful state-of-the-art facility
• Diversity and Inclusion
• Corporate Social Responsibility Program and partnership with charitable organization
• Strong value placed on company culture
• Excellent, comprehensive insurance coverage that includes Medical, Vision, and Dental benefits. 
• Opportunities for career growth and advancement
• Employee discount on Sunstar products
• 401K retirement plan with employer match (Pretax and Roth options)
• 401K profit sharing contribution based on company performance.
• Paid holidays and generous paid time off. Pet, Legal and Identity Theft Insurance Plans
• Competitive bonus
• On-site café
• On Site Fitness Center
• Corporate Perks Discount Program (Auto, Retail, Electronics, Entertainment, Computers, Personal Vacations, Cell Phones, Movie Tickets, Eating Out and Much More)
• Holiday Lunches
• Beautifully maintained walking trails
• Hybrid Schedule (certain departments)
• Numerous employee appreciation events throughout the year.
• Recognition and Rewards Programs
• Anniversary, Birthday and New Hire Announcements

 If you’d enjoy a career helping others attain overall health through oral health, consider joining the Sunstar Americas, Inc. team.

The employer is subject to certain governmental record keeping and reporting requirements for the administration of civil rights laws and regulations. In order to comply with these laws, the employer invites employees to voluntarily self-identify their gender, and race or ethnicity. Completion of this data is voluntary and will not affect your opportunity for employment or terms or conditions of employment. Information collected will be used for EEO-1 reporting purposes only and will be kept separate from all other personnel records, only accessed by Authorized Users. Information collected will be kept confidential and will only be used in accordance with the provisions of applicable laws, including those that require the information to be summarized and reported to the federal government. When reported, data will not identify any specific individual. 

The pay range for this position Sr. Process Technician is $34.36 to $42.95. However, base pay offered may vary depending on skills, experience, job-related knowledge and location. This position is also eligible for a bonus depending on company performance.