Sr Process Engineer Jobs in Kentucky (NOW HIRING)

The Process Engineer is responsible for supporting both new product launches and ongoing production operations within the injection molding department. This role serves as the technical expert for molding processes, process optimization, troubleshooting, and continuous improvement activities while ensuring products consistently meet customer, quality, delivery, and cost requirements. The Process Engineer partners with Operations, Maintenance, Quality, Tooling, and Program Management to successfully launch new programs, improve process capability, reduce scrap, increase productivity, and support operational excellence in a high-volume automotive manufacturing environment.Job Responsibilities:Develop, establish, optimize, and maintain injection molding processes to achieve safety, quality, delivery, and productivity objectives.Support new product launches by participating in APQP activities, process development, mold trials, run-at-rate events, PPAP submissions, and customer launch requirements.Lead process validation activities including machine parameter development, window studies, capability studies, and production readiness evaluations.Troubleshoot molding defects, process variation, tooling concerns, and equipment issues using structured problem-solving methodologies.Analyze process performance data and implement corrective actions to improve quality, efficiency, and overall equipment effectiveness (OEE).Collaborate with Tooling, Maintenance, Production, and Quality teams to resolve technical issues and support stable production operations.Monitor and improve key manufacturing metrics including scrap, cycle times, downtime, labor efficiency, productivity, and process capability.Develop and maintain process documentation including setup sheets, process parameters, work instructions, PFMEAs, control plans, and standardized work.Identify and implement continuous improvement initiatives focused on waste reduction, cycle time improvement, cost reduction, and operational efficiency.Support mold qualification activities, tooling changes, engineering changes, and customer-driven modifications.Assist in equipment selection, process development, automation implementation, and capacity planning for new and existing programs.Conduct root cause investigations and lead corrective action activities related to internal defects, customer complaints, and warranty concerns.Train and support Production Supervisors, Process Technicians, and operators on process standards and best practices.Participate in layered process audits, quality audits, and customer audits as required.Support material evaluations, process trials, and new technology implementation initiatives.Analyze production capacity, machine utilization, and cycle times to identify constraints, support customer demand requirements, and develop plans to optimize available capacity.Lead capacity planning activities for new program launches and existing production, including equipment requirements, tooling needs, labor utilization, and future growth projections.Evaluate production performance against capacity models and implement process improvements to increase throughput, reduce bottlenecks, and improve overall equipment effectiveness (OEE).Collaborate with Operations and Program Management to support quote reviews, feasibility assessments, and capacity studies for new business opportunities.Ensure compliance with IATF 16949, customer-specific requirements, environmental requirements, and company policies.Support additional manufacturing operations and special projects as assigned to meet business needs.Job Qualifications:Bachelor's Degree in Engineering (Mechanical, Manufacturing, Plastics, Industrial, or related discipline) preferred.Minimum 3-5 years of engineering experience in automotive manufacturing, preferably within injection molding operations.Strong knowledge of injection molding processes, scientific molding principles, polymer materials, and mold design fundamentals.Experience supporting automotive program launches, APQP, PPAP, PFMEA, Control Plans, and customer-specific requirements.Demonstrated ability to troubleshoot molding defects such as short shots, flash, sinks, warpage, splay, burn marks, and dimensional concerns.Experience with process optimization, cycle time reduction, scrap reduction, and process capability improvement.Knowledge of Lean Manufacturing, Continuous Improvement, and structured problem-solving methodologies.Familiarity with robotics, automation systems, hot runner systems, mold temperature control systems, and auxiliary equipment.Experience utilizing SPC, process capability studies, MSA, and data analysis tools.Strong project management, organization, and communication skills.Proficiency with Microsoft Office, ERP systems, and manufacturing data collection systems.Ability to read and interpret engineering drawings, GD&T, specifications, and technical documentation.Strong analytical and root-cause investigation skills.Ability to manage multiple projects and priorities in a fast-paced automotive manufacturing environment.