The Polymer Processing Engineer is responsible for the implementation of fully qualified and documented processes. This involves transitioning new tooling programs, performing new mold and process improvement mold trials, troubleshooting production processes and auditing of production set-ups for adherence to the documented processes, and identifying automation and productivity improvement opportunities.
KEY RESPONSIBILITIES
1. Ensures required process development information accompanies new tooling.
2. Interpret processes received and makes necessary conversions for production equipment to be used.
3. Interact with Tooling Engineers and Scheduling to ensure timely scheduling of mould tests.
4. Sets moulds to be tested.
5. Record and maintain mould and process setup sheets.
6. Improves and documents processes on existing moulds, using established systematic techniques.
7. Assists in trouble-shooting production processes.
8. Assists in training of new process technicians and mould setup personnel.
9. Conducts cycle improvement and regrind usage tests.
10. Identifies key process parameters for process monitoring and control.
11. Establishes process parameters for part diversion.
12. Audits production processes for adherence to established setup.
13. Assists with investigations of reject product and the development of corrective actions.
14. Conducts D.O.E.s.
15. Participate in cost saving and continuous improvement activities using Six Sigma Principles.
16. Identify and execute cost savings opportunities including cycle reduction, mold change times (SMED), scrap and labor reductions.
QUALIFICATIONS
17. Minimum of 3 years’ experience in injection molding processing.
18. Relevant 3rd level Qualifications, with a focus on plastics processing desirable.
19. Must have comprehensive knowledge and thorough understanding of injection molding process, machines, robotics, and auxiliary equipment.
20. Knowledge of ISO standards, TQM, and GMP’s is highly desirable.
21. Ability to write reports, business correspondence, and procedure manuals.
22. Ability to effectively present information and respond to questions from management, clients, customers, and manufacturing personnel.
23. Ability to define problems, collect data, establish facts, and draw valid conclusions.
24. Ability to take a systematic approach to process optimisation and problem solving.
25. Experienced with hot runner systems and knowledgeable in precision injection mould tooling.
26. Knowledge in resin structure and behavior when processed, including stress, orientation and melt rheology as well as resin drying and testing.
27. Extensive hands-on experience with the entire injection moulding process, should be familiar with machinery up to a press capacity of 500 tons.
28. Up-to-date knowledge of injection moulding machine technology and capabilities.
29. Skilled in basic metrology; working knowledge of geometric tolerancing and ability to interpret drawings; and some experience in designing and perform DOE’s and process statistical capability studies.
30. Excellent organisational, planning, and analytical skills; strong knowledge of MS Word and Excel.
31. Knowledge in mould design essential.