Senior Process Engineer at TRS Staffing Solutions

Job Title: Senior Process Engineer – Injection Molding

Location: Travelers Rest, SC

Industry: plastic injection molding manufacturing

Status of Hire: direct placement; permanent

Reports to: Site Operations Manager

Pay: $85k-$120k

Benefits: Medical (Employer pays 60%-75% of the premiums), Dental, Vision, 4 weeks PTO, LTD, STD, and more!

Summary: The Senior Process Engineer / Technical Expert for our Injection Molding Facility will serve as the go-to subject matter expert (SME) in injection molding processes, driving technical excellence, innovation, and optimization. This role will lead the development of new processes, solve complex technical challenges, and serve as a key technical resource for the production team, ensuring the highest standards in efficiency, quality, and sustainability. The individual will act as the technical leader in injection molding, guiding the team in troubleshooting, process development, and implementing best practices across all stages of production.

Job Duties:

• Act as the primary technical authority in the injection molding process, providing guidance and support across all levels of the organization.
• Lead the development and optimization of injection molding processes, utilizing advanced techniques and technologies to ensure high efficiency, quality, and cost-effectiveness.
• Champion continuous improvement initiatives using tools like Six Sigma, Kaizen, and Lean manufacturing, while driving process innovation and the adoption of new technologies
• Develop and implement advanced molding processes, including the selection of materials, molding parameters, and tooling, for new and existing products.
• Research and integrate emerging technologies such as automation, robotics, and smart manufacturing techniques to improve productivity and part quality.
• Lead the development of highly complex injection molding projects, including new product designs, advanced material formulations, and custom molds.
• Provide technical troubleshooting for complex molding issues, including part defects, material inconsistencies, and equipment failures.
• Serve as the first point of contact for identifying root causes and implementing corrective actions for difficult or recurring problems.
• Lead detailed failure analysis of molds, processes, and materials to mitigate risks and improve overall system reliability.
• Serve as a mentor and technical resource for junior engineers, operators, and production staff, fostering a culture of knowledge sharing and technical excellence.
• Provide training programs and workshops on advanced injection molding techniques, best practices, and process control methods for employees at all levels.
• Facilitate technical sessions and promote knowledge transfer across teams to ensure continued growth and skill development within the team.
• Oversee process controls to ensure consistency in production, meeting customer specifications and quality standards.
• Develop and maintain advanced statistical process control (SPC) systems and quality monitoring tools to enhance production consistency and reduce defects.
• Define proactive preventive maintenance strategies to ensure optimal performance of machinery and tooling, minimizing downtime and maximizing throughput.
• Collaborate with R&D, Design, Quality, and Production teams to design, implement, and optimize processes that support new product development and product launches.
• Advise on material selection, tooling, and design adjustments to ensure manufacturability, cost-effectiveness, and product performance.
• Lead efforts to reduce cycle times, material waste, energy consumption, and operational costs while improving overall productivity.
• Implement advanced techniques like value stream mapping, root cause analysis, and Pareto analysis to drive cost-saving initiatives and eliminate inefficiencies.
• Support capacity planning and resource allocation to ensure efficient use of equipment, personnel, and materials, and drive scalability for high-volume production.
• Act as the technical liaison between the company and external stakeholders, including suppliers, customers, and partners, to ensure product and process specifications are met.
• Provide technical support and troubleshoot issues in customer-facing projects, offering guidance on design changes and solutions for complex molding challenges.
• Ensure that all injection molding processes meet safety regulations and comply with industry standards (ISO, FDA, etc.).
• Promote a culture of safety first, ensuring all employees are trained on safety protocols and that any potential safety hazards are identified and mitigated.
• Work with multiple press variations including Sumitomo, Nissei, Arburg, and Netstal 50t-300t.
• Working with process technician teams of varying levels of expertise

Qualifications and Requirements:

• Bachelor’s degree in Mechanical Engineering, Plastics Engineering, or a related technical field. Master’s degree is a plus.
• 5-7 years of hands-on experience in injection molding with a proven track record of successfully developing, optimizing, and troubleshooting complex processes.
• Must have excellent verbal and written communication skills with the ability to influence stakeholders at all levels and foster collaboration
• Software (preferred, not required): InTouch, eDART process control system, Keyence vision system, MS Office
• Must have extensive experience in advanced injection molding technologies, mold design, and materials science
• Must be proficient in process simulation, mold flow analysis, and computer-aided engineering (CAD) tools
• Expertise in process control techniques such as SPC, Six Sigma, FMEA, and root cause analysis is strongly preferred
• Must have familiarity with automation, robotics, and smart manufacturing in injection molding operations
• Must be willing to travel occasionally for vendor support, customer interaction, and cross-functional collaboration
• Six Sigma Black Belt, Lean Manufacturing, or equivalent certifications are highly preferred.
• Physical demands of this role include the ability to lift up to 25lbs, prolonged periods of standing, walking, or sitting, and manual dexterity for equipment handling and process adjustments. Production floor presence is essential to this role. This position will have to adhere to all relevant safety standards.

**Must be authorized to work in the United States, client is not able to offer sponsorship at this time

**Must be able to pass a pre-employment drug test, background check, and physical to be eligible for hire (physical will include respirator fitting)

We are an equal opportunity employer that recognizes the value of a diverse workforce. All qualified individuals will receive consideration for employment without regard to race, color, age, sex, sexual orientation, gender identity, religion, national origin, disability, veteran status, genetic information, or any other criteria protected by governing law.