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Process Engineer (Rockford)
Process Engineer (Rockford)Brightpath Associates LLC • Rockford, IL, US
Process Engineer (Rockford)

Process Engineer (Rockford)

Brightpath Associates LLC • Rockford, IL, US
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Process Engineer Plastics (Injection Molding)

Location : Rockford, IL

Employment Type : Full-Time

Position Summary

The Process Engineer is responsible for developing, optimizing, and troubleshooting high-speed plastic injection molding processes, with a concentration on thin-wall packaging applications. This role partners closely with Process Technicians, Tooling, Quality, Maintenance, and cross-functional manufacturing teams to improve cycle times, reduce scrap, increase efficiency, and support new product introductions. The ideal candidate has hands-on experience in scientific molding, DOE studies, automation integration, and continuous improvement within a fast-paced plastics manufacturing environment.

Key Responsibilities

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, and downtime.
  • Lead process validation activities, including DOE, IQ / OQ / PQ protocols, and capability studies.
  • Ensure compliance with GMP / SQF, safety, environmental, and regulatory standards.

Troubleshooting & Collaboration

  • Partner with Quality, Tool Room, Maintenance, and Production to resolve part defects and molding issues.
  • Evaluate mold performance and recommend tooling improvements.
  • Support predictive and preventive maintenance initiatives to improve uptime and equipment reliability.
  • Work with Project Management to support new product launches and equipment upgrades.

    • Automation & System Integration

  • Integrate molding cells with robotics, vision inspection, and downstream 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 and Six Sigma initiatives to improve OEE and reduce waste.
  • Conduct labor studies, cycle time analysis, and process capability improvements.
  • Drive cost-saving initiatives using Six Sigma methodologies and project charters.

    • Qualifications

    Education & Experience

  • Bachelors Degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, or related field (or equivalent experience).
  • 5+ years of hands-on plastic injection molding experience in a manufacturing setting.
  • High-speed, thin-wall injection molding experience required.
  • Experience developing scientific molding processes from the ground up.
  • Experience conducting DOE studies and validating molding processes (IQ / OQ / PQ).
  • Experience integrating robotics, automation, and high-speed packaging systems.
  • Formal training in scientific molding or RJG certification preferred.
  • Lean Manufacturing or Six Sigma certification a plus.
  • Technical Competencies
  • Strong understanding of polypropylene, polyethylene, and other packaging-grade resins.
  • Ability to read and interpret SPC charts and improve process capabilities.
  • Proficient in Microsoft Office; experience with ERP / MES systems.
  • Strong understanding of OEE and ability to drive measurable improvements.
  • Competent in root cause analysis and structured problem-solving.
  • Soft Skills & Attributes
  • Hands-on, collaborative team player.
  • Strong analytical and troubleshooting skills.
  • Ability to work in a fast-paced, high-volume production environment.
  • Effective communication across cross-functional teams.
  • Detail-oriented with a passion for efficiency and quality.

    • Relationships

  • Works closely with all departments including Production, Quality, Tool Room, Maintenance, and Engineering.

    • Supervisory Responsibilities

  • None
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