{"id":2106230,"url":"https://alion.io/job/clayens-injection-molding-process-engineer","title":"Injection Molding Process Engineer","company":{"id":3913427,"name":"Clayens","domain":"clayens.com","url":"https://alion.io/company/clayens","size_band":"501-1000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"ADP","truth_index":{"grade":"B","score":75,"open_postings":7,"ghost_share":0,"stale_share":1,"repost_share":0,"time_to_fill_p50_days":null,"computed_at":"2026-10-12T06:55:09Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"middle","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Greeneville, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":70000,"max":90000,"currency":"USD","period":"year","gross":null,"usd_annual":90000},"salary_estimate":null,"experience_years_min":3,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Microsoft Office","optional":false}],"status":"live","first_seen_at":"2026-08-12T18:25:00Z","employer_posted_date":"2026-08-12","last_verified_at":"2026-10-12T16:08:09Z","board_verified":true,"closed_at":null,"days_open":61,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":61},"description":"Plastic Injection Molding Process Engineer\nJob Summary\nThe Plastic Injection Molding Process Engineer is responsible for developing, optimizing, validating, and sustaining injection molding processes to ensure safe, efficient, and high-quality production. This position works closely with Operations, Quality, Tooling, Maintenance, Engineering, and Program Management teams to improve manufacturing performance, reduce costs, support new product launches, and drive continuous improvement initiatives throughout the molding operation.\nReports To: Operations Manager\nEssential Duties and Responsibilities\nDevelop, establish, validate, and document robust injection molding processes for new and existing products.\nLead process development activities, including mold trials, process studies, capability analysis, and production validations.\nAnalyze molding processes and implement improvements to increase productivity, quality, and overall equipment effectiveness (OEE).\nTroubleshoot molding defects, including flash, short shots, sink marks, burn marks, splay, warpage, dimensional variation, and cosmetic defects.\nUtilize scientific molding principles and data-driven methodologies to establish and maintain process controls.\nConduct root cause investigations and implement corrective and preventive actions for process-related issues.\nSupport new product launches, process qualifications, mold validations, and production ramp-ups.\nDevelop and maintain standard process sheets, work instructions, validation documentation, and engineering records.\nCollaborate with Quality to establish process capability requirements and improve product consistency.\nIdentify opportunities to reduce cycle times, scrap, downtime, material consumption, and manufacturing costs.\nEvaluate and implement process improvements involving automation, robotics, vision systems, and auxiliary equipment.\nPartner with Tooling and Maintenance teams to improve mold performance, reliability, and preventive maintenance programs.\nLead continuous improvement projects utilizing problem-solving methodologies.\nSupport production teams by providing technical guidance and training on molding processes and best practices.\nParticipate in customer audits, quality investigations, and corrective action activities as required.\nEnsure compliance with safety, environmental, and company policies.\nRequired Qualifications\nBachelor's degree in Engineering, Plastics Engineering, Manufacturing Engineering, Mechanical Engineering, or a related technical field.\nMinimum of 3 to 7 years of experience in plastic injection molding process engineering or advanced process development.\nStrong knowledge of injection molding equipment, molds, tooling, and resin processing.\nExperience developing and validating molding processes in a manufacturing environment.\nKnowledge of scientific molding principles and process optimization techniques.\nExperience with root cause analysis, statistical methods, and process capability analysis.\nAbility to read and interpret engineering drawings, GD&T, specifications, and quality standards.\nProficiency with Microsoft Office and manufacturing software systems.\nExcellent analytical, organizational, and problem-solving skills.\nStrong communication and project management abilities.\nPreferred Qualifications\nBachelor's degree in Plastics Engineering.\nRJG Master Molder Certification or equivalent Scientific Molding certification.\nExperience with automation systems, robotics, and machine vision technologies.\nExperience in automotive, medical, consumer products, or other high-volume injection molding environments.\nKnowledge of DOE (Design of Experiments), Moldflow analysis, and process capability studies.\nKnowledge, Skills, and Abilities\nInjection molding process development and optimization.\nScientific molding and process validation methodologies.\nPlastic resin behavior, material drying, and material handling systems.\nStatistical Process Control (SPC) and process capability analysis.\nRoot cause analysis and corrective action implementation.\nContinuous improvement methodologies.\nProject leadership and cross-functional collaboration.\nAutomation and manufacturing technology integration.\nStrong technical writing and documentation skills.\nExcellent verbal and written communication skills.\nPhysical Requirements\nAbility to stand, walk, and move throughout the manufacturing facility for extended periods.\nAbility to occasionally lift up to 35 pounds.\nAbility to inspect molds, machines, and manufacturing equipment.\nFrequent reaching, bending, and interaction with manufacturing equipment.\nAbility to safely wear required personal protective equipment (PPE).\nWork Environment\nManufacturing environment with exposure to moving machinery, noise, heat, and plastic processing equipment.\nFrequent interaction with production, tooling, engineering, and maintenance personnel.\nOccasional travel may be required to suppliers, customers, or other company facilities.\nMay require schedule flexibility to support process trials, launch activities, and critical production needs.\nKey Performance Indicators (KPIs)\nScrap Reduction\nOverall Equipment Effectiveness (OEE)\nCycle Time Reduction\nFirst Pass Yield (FPY)\nProcess Capability (Cp/Cpk)\nCost Reduction Achievement\nDowntime Reduction\nNew Product Launch Success\nProcess Validation Completion\nContinuous Improvement Project Results\nCustomer Quality Performance\nSafety Performance\nSuccess Factors\nEstablishes repeatable and robust molding processes.\nReduces process variation and manufacturing costs.\nImproves productivity and equipment utilization.\nSuccessfully supports new product introductions and transfers.\nDrives data-based decision-making and continuous improvement.\nActs as the technical expert for injection molding process performance and 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