Process Engineer
Confirmed on the employer's own hiring board on Oct 20, 2026. First seen by Alion on Oct 20, 2026. Koch Industries scores A on the Alion truth index.
Your Job
As a Process Engineer based in Costa Mesa, California, you will develop, validate, improve, and sustain manufacturing processes for injection-molded and over molded medical-device and cable-assembly products. You will serve as the technical owner for molding and over molding processes from concept through production release, helping deliver safe, capable, efficient, and compliant manufacturing operations.
This role provides technical leadership for new product introductions, process transfers, tooling development, scientific molding studies, process validation, and continuous improvement. The primary focus is thermoplastic injection molding and component or cable over molding.
Our Team
You will collaborate with manufacturing operations, quality, project engineering, tooling and equipment suppliers, customers, technicians, and other cross-functional partners. The team supports new-product development and existing production by translating technical challenges into practical, production-ready manufacturing solutions.
What You Will Do
- Develop and optimize thermoplastic injection-molding and overmolding processes using scientific molding principles, design of experiments, capability studies, and data-driven analysis
- Lead molding process development for new product introductions, product transfers, prototype builds, validation activities, production launches, and sustaining products
- Establish robust process windows and resolve molding defects, including flash, short shots, sink, voids, burns, flow lines, delamination, cosmetic issues, and overmold bonding failures
- Support mold design reviews and design-for-manufacturability activities, and coordinate mold fabrication, qualification, debugging, acceptance, and production readiness
- Specify and qualify molding machines, fixtures, automation, auxiliary equipment, material-handling systems, and inspection equipment
- Develop and execute engineering and validation studies, including equipment qualification and installation qualification, operational qualification, and performance qualification activities
- Author and review engineering protocols, validation protocols, final reports, process documentation, risk assessments, process failure mode and effects analyses, control plans, and process-change assessments
- Lead root-cause analysis, corrective actions, and improvements related to scrap, defects, cycle time, overall equipment effectiveness, yield, capacity, cost, and recurring process disruptions
- Train technicians, operators, and engineering personnel on new or revised processes and monitor sustained process capability after implementation
Who You Are (Basic Qualifications)
- Bachelor’s degree in mechanical engineering, manufacturing engineering, plastics engineering, industrial engineering, or another engineering discipline
- 5+ years of manufacturing or process engineering experience
- 3+ years of hands-on thermoplastic injection-molding or over molding experience
- Experience with scientific molding, thermoplastic material behavior, material drying, process-window development, design of experiments, capability analysis, root-cause analysis, or process validation
- Experience developing or sustaining manufacturing processes in a production environment
What Will Put You Ahead
- Experience in medical-device or another regulated manufacturing environment
- Experience with cable-assembly molding and overmolding
- Experience with silicone molding or silicone overmolding
- Experience with insert molding, multi-shot molding, automation, robotics, or vision-inspection systems
- Experience with installation qualification, operational qualification, and performance qualification validation activities
- Experience with SolidWorks or equivalent computer-aided design software
- Experience applying Lean or Six Sigma methods to improve scrap, cycle time, yield, capacity, or manufacturing cost
This role is not eligible for VISA Sponsorship.
For this role, we anticipate paying $105,000 - $120,000 per year. This role is eligible for variable pay, issued as a monetary bonus or in another form.
At Koch companies, we are entrepreneurs. This means we openly challenge the status quo, find new ways to create value and get rewarded for our individual contributions. Any compensation range provided for a role is an estimate determined by available market data. The actual amount may be higher or lower than the range provided considering each candidate's knowledge, skills, abilities, and geographic location. If you have questions, please speak to your recruiter about the flexibility and detail of our compensation philosophy.
Hiring Philosophy
All Koch companies value diversity of thought, perspectives, aptitudes, experiences, and backgrounds. We are Military Ready and Second Chance employers. Learn more about our hiring philosophy here.
Who We Are
At Koch, employees are empowered to do what they do best to make life better. Learn how our business philosophy helps employees unleash their potential while creating value for themselves and the company.
Our Benefits
Our goal is for each employee, and their families, to live fulfilling and healthy lives. We provide essential resources and support to build and maintain physical, financial, and emotional strength - focusing on overall wellbeing so you can focus on what matters most. Our benefits plan includes - medical, dental, vision, flexible spending and health savings accounts, life insurance, ADD, disability, retirement, paid vacation/time off, educational assistance, and may also include infertility assistance, paid parental leave and adoption assistance. Specific eligibility criteria is set by the applicable Summary Plan Description, policy or guideline and benefits may vary by geographic region. If you have questions on what benefits apply to you, please speak to your recruiter.
Additionally, everyone has individual work and personal needs. We seek to enable the best work environment that helps you and the business work together to produce superior results.
Equal Opportunities
Equal Opportunity Employer, including disability and protected veteran status. Except where prohibited by state law, some offers of employment are conditioned upon successfully passing a drug test. This employer uses E-Verify. Please click here for additional information. (For Illinois E-Verify information click here, aquí, or tu).