Senior Process Engineer Jobs in Dry Ridge, KY (NOW HIRING)

This Process Engineer role focuses on optimizing mold designs and implementing plastic extrusion and plastic molding manufacturing processes from pilot through full-scale operations. The position drives efficiency, quality, and functionality of molded products by developing robust processes, conducting experiments and tests, and supporting tooling and equipment implementation. The Process Engineer serves as a subject matter expert for new and existing products, working closely with engineering, operations, quality, and customers to ensure stable, repeatable, and cost-effective manufacturing.

• Perform mold process development using a scientific approach to achieve optimal processes that meet quality, productivity, and reliability specifications.
• Develop, implement, and document procedures to define and report process parameters from setup through production scheduling, ensuring consistent and reliable operations.
• Establish and refine manufacturing process parameters on existing molds using techniques such as mold balance analysis, gate freeze studies, and relative viscosity studies to ensure stable and repeatable processes.
• Provide direction and technical guidance to supervisors and quality personnel to support mold maintenance, repair, and cleaning while fostering a relationship of trust and collaboration.
• Build and maintain positive customer relationships by delivering effective sampling results and providing solutions to production problems.
• Recommend designs for special equipment and assist production teams with product and process research and development programs.
• Maintain and train others on the proper maintenance and use of product-specific equipment such as robots, hot runner systems, and related tooling.
• Evaluate plastic processing and support equipment to identify opportunities for productivity improvement, quality enhancement, and cost reduction.
• Stay current on methods, systems, and equipment in plastics processing to continuously improve quality and productivity.
• Create and maintain accurate documentation for all samples, processes, production items, issues, and related technical information.
• Support new business development, engineering, and operations as a subject matter expert in designing, developing, and sourcing tooling that meets functional and cost objectives for new products.
• Plan and run experiments and tests to improve manufacturing procedures, processes, and part designs, ensuring data-driven decision-making.
• Execute designed experiments (DOEs), analyze results, report findings, and create or update standard operating procedures (SOPs) based on outcomes, while maintaining complete observation and experiment records.

• Bachelor’s degree in an Engineering discipline or equivalent experience.
• Approximately five years of experience in manufacturing processes, design engineering, automation, and project management, with demonstrated ability to develop unique and innovative design solutions.
• Hands-on experience with plastics processing and plastic injection molding, including process improvement and process engineering.
• Strong understanding of modern injection molding techniques and processes.
• Familiarity with scientific analysis methods such as Design of Experiments (DOE), Statistical Process Control (SPC), Mold Flow analysis, and Failure Modes and Effects Analysis (FMEA).
• Proven ability to use a systematic approach to problem solving, including analyzing issues and evaluating alternative solutions.
• Demonstrated ability to start and persist with specific courses of action, showing high motivation and a strong sense of urgency.
• Experience with 3D CAD tools, with preference for SolidWorks, to support design and process development activities.
• Strong organizational and planning capabilities with exceptional problem prevention and problem-solving skills.
• High attention to detail with the ability to meet deadlines on complex projects and perform effectively in a fast-paced environment.
• Excellent teamwork and communication skills, with the ability to work through others to get things done and meet commitments.
• Ability to establish effective working relationships at all levels within the organization and with customers and suppliers.

• Bachelor’s degree specifically in Plastics Engineering is highly desirable.
• Master mold certificate is a plus.
• Experience working in plastics or injection molding environments with at least five years of process experience.
• Experience applying Lean manufacturing principles in a plastics or injection molding context.
• Experience with injection mold design and optimization.
• OEM-specific certifications are considered an advantage.
• Additional experience with SolidWorks beyond basic proficiency is beneficial.
• Demonstrated experience in plastic extrusion and plastic molding process implementation from pilot to full-scale production.
• Experience evaluating and implementing robotics, hot runner systems, and other specialized plastic processing equipment.

This is a fully on-site role with a standard Monday through Friday schedule. The Process Engineer works in a manufacturing environment focused on plastic extrusion and plastic molding, including plastic injection molding operations. The role involves close interaction with production floors, tooling areas, and engineering offices, using technologies such as 3D CAD (including SolidWorks), robots, hot runner systems, and other plastic processing and support equipment. The environment is fast-paced and project-driven, requiring coordination across engineering, operations, quality, and customer-facing teams, with a strong emphasis on continuous improvement, process stability, and product quality.

This is a Permanent position based out of Erlanger, KY.

The pay range for this position is $100000.00 - $115000.00/yr.

Full Dental, Medical, Vision, 401k match

This is a fully onsite position in Erlanger,KY.

This position is anticipated to close on Aug 14, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

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