Manufacturing Engineer - Plastics & Injection Molding

Our employer is a leading provider of premium metal payment cards and secure authentication solutions. Headquartered in New Jersey, the company serves major financial institutions, producing over 30 million metal cards annually and holding a dominant share in the premium metal card segment. It also offers advanced digital security through a proprietary platform that includes three-factor authentication and cold storage for digital assets, generating over $420 million in annual sales.

Position Overview:

We are seeking an Advanced Manufacturing Engineer with specialized expertise in plastics manufacturing, particularly injection molding. The ideal candidate will have a strong understanding of injection molding processes, tooling, mold design, injection machines, and auxiliary equipment to support production. In addition to plastics expertise, this role will drive manufacturing excellence through yield improvement, process optimization, defect analysis, and automation integration.

This position plays a crucial role in ensuring high-quality, efficient production while identifying and implementing process improvements. The ideal candidate will have a background in automation, system design, and defect analysis in plastic components.

The Advanced Manufacturing Engineer will work out of Somerset, NJ location 5 days a week and report to the Director, Advanced Technologies.

Key Responsibilities:

Plastics & Injection Molding Focus

Injection Molding Process Optimization: Improve molding processes, reduce cycle times, and enhance efficiency while maintaining high product quality.

Tooling and Mold Design: Work with the tooling team to develop and optimize molds, ensuring manufacturability, cost-effectiveness, and longevity.

Equipment Management: Oversee the selection, installation, and maintenance of injection molding machines and auxiliary equipment to ensure smooth production operations.

Material Processing: Understand material behavior in injection molding and optimize process parameters for different resin types.

Defect Analysis & Troubleshooting: Conduct in-process and post-production defect analysis for surface defects, sink marks, short shots, and warping, implementing corrective actions.

Manufacturing Process Optimization & Automation

Yield Improvement: Analyze production processes to enhance yield, reduce scrap, and improve efficiency.

Automation & Machine Integration: Collaborate with automation engineers to integrate robotics, PLCs, and vision systems into molding and assembly lines.

Data-Driven Process Improvement: Use SPC, Six Sigma, and DoE methodologies to improve manufacturing efficiency.

Cross-Functional Collaboration: Work with R&D, Operations, and Quality teams to align on process improvements, new product launches, and validation.

Continuous Improvement: Lead initiatives for cost reduction, cycle time improvement, and overall manufacturing efficiency.

Qualifications:

Education: Bachelor's degree in Plastics Engineering, Mechanical Engineering, Manufacturing Engineering, or a related field.

Experience: 5+ years of experience in injection molding, process improvement, automation, or yield optimization in a manufacturing environment.

Technical Expertise:

Strong knowledge of injection molding processes, mold design, toolmaking, injection machines, and auxiliary equipment.

Understanding material science related to plastics, including shrinkage, viscosity, and cooling rates.

Experience with surface defect engineering and defect analysis in molded components.

Automation Knowledge: Familiarity with PLC programming, robotic automation, and vision systems for quality control.

Problem-Solving & Analytical Skills: Proven ability to troubleshoot molding issues, conduct root cause analysis, and implement corrective actions.

Lean & Six Sigma Experience: Understanding of SPC, DoE, Lean Manufacturing, and process control strategies to drive continuous improvement.