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Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.

Job Title

Sr. Process Engineer

Location

Lincolnshire, IL

About Us

Imagine a company with technology leadership of over 160 years, yet it operates with the energy of a startup. Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission‑critical flow creation and life science technologies – from compressors to precision handling of liquids, gases, and powers – to increase industrial productivity, efficiency, and sustainability. Supported by over 80+ brands, our products are used in various end‑markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more.

Job Overview

The Process Engineer is responsible for the development, optimization and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The Process Engineer plays a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues and ensuring stable manufacturing performance across all molding work centers. The Process Engineer collaborates closely with the Tooling, Production, Quality, NPI and Maintenance teams to ensure successful product launches, consistent quality and efficient manufacturing processes.

Responsibilities Process Development & Optimization

• Develop, validate and optimize molding processes for HCR injection, compression and transfer molding.
• Multi‑cavity, family molds and multi‑shot configurations.
• Apply scientific molding techniques to establish pack/hold strategies.
• Establish cure and thermal control profiles.
• Set venting and flash prevention parameters.
• Perform process determination and DOE studies to improve capability (Cp/Cpk) and reduce variation.
• Establish and maintain standardized process parameter sheets, recipes and work instructions.

Troubleshooting & Technical Support

• Provide daily technical support to address molding issues such as flash, short shots, cure variations, knit lines and voids.
• Address sticking and ejection problems.
• Resolve inconsistent shrink, durometer and dimensional stability.
• Lead structured root cause analysis (5 why, 8D, fishbone) and implement corrective and preventative actions.
• Train operators and technicians in molding best practices and process discipline.

Tooling & Equipment Interaction

• Partner with Tooling Engineer on gate/vent design for silicone and rubber molds, cold runner or valve‑gate LSR systems, mold thermal management and vent maintenance, mold qualification and production readiness.
• Support maintenance to ensure equipment operates within validated performance parameters.
• Provide feedback to improve mold robustness, reduce tool wear and minimize flash‑related issues.
• Drive improvements in cycle‑time optimization, scrap and rework reduction, OEE, material usage and yield optimization.
• Participate in LEAN, Kaizen, 5S and efficiency projects.
• Use SPC, data analytics and process monitoring to identify and address instability.

Cross‑Functional Collaboration

• Work with NPI Engineering on feasibility reviews, new mold trials and qualification, launch readiness and transfer to production.
• Support quoting/estimating with cycle‑time projections and cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks and improvement projects.

General Accountability

• Cooperation and professional conduct with coworkers, staff, and managers.
• Communicate effectively with Flexan’s employees and management, demonstrating all corporate values.
• Quality, accountability, respect, integrity, open & honest communication, teamwork.

Requirements

• Bachelor’s degree in Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer).
• 5+ years’ direct experience in silicone and/or rubber molding, with strong understanding of HCR molding, compression and transfer molding, cure cycles, post‑cure and material behavior.
• Experience using DOE, SPC and statistical tools for process improvement.
• Strong ability to interpret engineering drawings, GD&T, CAD models, customer and regulatory specifications.
• Demonstrated success in troubleshooting complex molding issues.

Preferences

• Experience with SolidWorks or other 3D modelling software.
• Experience with mold flow analysis (or ability to interpret results).
• Background in medical, automotive, aerospace or industrial silicone components.
• Experience supporting APQP, PPAP and customer audits.
• Experience with automation, vision inspection and deflashing/trimming technologies.
• Background with adhesion/bonding techniques, multi‑shot molding and overmolding.
• RJG/Paulson certification or silicone‑specific molding training.
• Familiarity with ISO13485 and clean room procedures is beneficial.

Travel & Work Arrangements / Requirements

Onsite.

Pay Range

$100–$125k.

Benefits

At Ingersoll Rand, we embrace a culture of personal ownership — taking responsibility for our company, our communities, and our environment, as well as our individual health and well‑being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401(k) plan, paid time off, and even an employee stock grant, among other offerings.

Disability Accommodation

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