Brightpath Associates LLC
Overview
Job Title – Process Engineer (Plastic)
Job Location – Rockford, IL
Client Summary –
We are a domestic packaging manufacturer specializing in highly decorated metal and plastic packaging solutions, designed to elevate and enhance the presentation of leading consumer brands
Job Summary The Process Engineer is responsible for the development, optimization, and troubleshooting of all plastic injection molding processes to ensure efficient, high-quality, and consistent production. This role works closely with Process Technicians, Tool Room personnel, Quality, Maintenance, and cross-functional manufacturing teams to improve cycle times, reduce scrap, maintain quality standards, and increase overall efficiency. The position also supports new product introductions, equipment upgrades, and continuous improvement initiatives in high-speed, thin-wall packaging applications.
Duties Process Development & Optimization
Develop, document, and optimize injection molding processes for new and existing molds.
Provide technical leadership and hands-on support to Process Technicians and Molding Operators.
Analyze process data and implement improvements to reduce cycle times, scrap rates, and downtime.
Lead process validation activities, including DOE, IQ/OQ/PQ protocols, and capability studies.
Ensure compliance with safety, environmental, and regulatory standards, including GMP/SQF where applicable.
Collaboration & Troubleshooting
Partner with Quality, Tooling, Maintenance, and Production teams to resolve part defects and mold issues.
Evaluate mold performance and recommend tooling improvements.
Support predictive and preventive maintenance strategies to improve uptime and reliability.
Collaborate with Project Management to support new product development and upgrades to molding, automation, and downstream packaging systems.
Automation & Technology Integration
Integrate high-speed molding cells with robotics, vision inspection, and downstream high-speed packaging systems.
Assist in selecting, installing, and commissioning injection molding machines and auxiliary equipment.
Implement automation improvements and labor optimization strategies.
Continuous Improvement & Efficiency
Lead and participate in Lean Manufacturing and Six Sigma initiatives to improve OEE and reduce waste.
Conduct labor studies, cycle time analysis, and process capability improvements.
Drive significant cost savings through CI projects utilizing a Six Sigma Project Charter.
Experience
Bachelor’s Degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, or a related technical field,
or equivalent experience .
Continuous Improvement Green Belt certification preferred.
CI experience leading a significant cost-saving project utilizing a Six Sigma Project Charter.
High-speed injection molding experience required, specifically in
thin-wall packaging applications
with extremely fast cycle times.
Experience developing scientific molding processes from the ground up.
Experience conducting DOE studies to validate and optimize molding parameters.
Experience with mold trials, start-up procedures, and process troubleshooting.
Experience integrating molding cells with robotics, vision inspection, and downstream packaging systems.
Knowledge of polypropylene, polyethylene, and other thin-wall packaging-grade resins, including shrinkage, flow, and cooling behavior.
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Job Location – Rockford, IL
Client Summary –
We are a domestic packaging manufacturer specializing in highly decorated metal and plastic packaging solutions, designed to elevate and enhance the presentation of leading consumer brands
Job Summary The Process Engineer is responsible for the development, optimization, and troubleshooting of all plastic injection molding processes to ensure efficient, high-quality, and consistent production. This role works closely with Process Technicians, Tool Room personnel, Quality, Maintenance, and cross-functional manufacturing teams to improve cycle times, reduce scrap, maintain quality standards, and increase overall efficiency. The position also supports new product introductions, equipment upgrades, and continuous improvement initiatives in high-speed, thin-wall packaging applications.
Duties Process Development & Optimization
Develop, document, and optimize injection molding processes for new and existing molds.
Provide technical leadership and hands-on support to Process Technicians and Molding Operators.
Analyze process data and implement improvements to reduce cycle times, scrap rates, and downtime.
Lead process validation activities, including DOE, IQ/OQ/PQ protocols, and capability studies.
Ensure compliance with safety, environmental, and regulatory standards, including GMP/SQF where applicable.
Collaboration & Troubleshooting
Partner with Quality, Tooling, Maintenance, and Production teams to resolve part defects and mold issues.
Evaluate mold performance and recommend tooling improvements.
Support predictive and preventive maintenance strategies to improve uptime and reliability.
Collaborate with Project Management to support new product development and upgrades to molding, automation, and downstream packaging systems.
Automation & Technology Integration
Integrate high-speed molding cells with robotics, vision inspection, and downstream high-speed packaging systems.
Assist in selecting, installing, and commissioning injection molding machines and auxiliary equipment.
Implement automation improvements and labor optimization strategies.
Continuous Improvement & Efficiency
Lead and participate in Lean Manufacturing and Six Sigma initiatives to improve OEE and reduce waste.
Conduct labor studies, cycle time analysis, and process capability improvements.
Drive significant cost savings through CI projects utilizing a Six Sigma Project Charter.
Experience
Bachelor’s Degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, or a related technical field,
or equivalent experience .
Continuous Improvement Green Belt certification preferred.
CI experience leading a significant cost-saving project utilizing a Six Sigma Project Charter.
High-speed injection molding experience required, specifically in
thin-wall packaging applications
with extremely fast cycle times.
Experience developing scientific molding processes from the ground up.
Experience conducting DOE studies to validate and optimize molding parameters.
Experience with mold trials, start-up procedures, and process troubleshooting.
Experience integrating molding cells with robotics, vision inspection, and downstream packaging systems.
Knowledge of polypropylene, polyethylene, and other thin-wall packaging-grade resins, including shrinkage, flow, and cooling behavior.
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