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Injection Molding Engineer

Athens, Alabama, United States
March 18, 2019

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***** ***** *****

Madison, AL *****


Stuart Smith

Self-motivated, self-directed Plastics Professional and RJG Master Molder II with over 25 years’ experience. I would like to make a significant impact on the company’s profitability and reputation.



Plastics Injection Molding Processing 25+ years in the industry

APQP Tooling and New Products development

RJG Master Molder I&II (Cert 354)Scientific Injection Molding (SIM)

Scientific new molding processes /optimize improving existing processes

Factorial DOE-Capability Study in

ISO13485 with IQ, OQ and PQ validation-cGMP

PFMEA, PPAP -process validation to R&R

Kaizen Champion Engineer

DFMs and engineering reviews for approval of tool and part design

Develop tooling BOMs Tooling repair, design and modified

Working with QMS with Automotive-TS16949

Gages, R&R optical comparator. OGP, GD&T, Drawing, 3D SolidWorks

3/2010 FMEA Certification and TS16949 Decatur, AL US

4/2008 NFPA 70E Arc Flash Assessment Certification Dothan, AL US

1/2008 RJG Master Molder I&II Certification (Cert 354) Clinton, MA US

6/2001 Axxicon Optical Disk Mold Repair and Maintenance Devens, MA. US

6/1998 Sumitomo Optical Disk Applications Engineer Norcross, Ga. US

7/1997 Rex Roth Hydraulics and closed loop control Allentown, Pa. US

5/1995 Allen-Bradley PLC-5 Programming and control Norcross, Ga. US

6/1991 Georgia Institute of Technology-Electrical Engineer Atlanta, GA US

MS Project




MS Office Suite

Lotus Notes


11/2016-Present KRAUSS MAFFEI CORP Madison, AL USA

Field Molding Engineer

Training for customers with controls and maintenance with new injection molding machines

Troubleshoot problems with new and used machines and software

Calibrations for mechanical, controls and software for Krauss Maffei injection molding machines.

Offer injection molding tooling, process and equipment optimization on service level.

Provide technical training for processing, controls and tooling to customer staff.

Develop training, molding and safety for process technicians and operators

03/2016-11/2016 SHAPE CORP/Automotive TS16949 Athens, AL USA

Injection Molding Engineer

Green Field operation start up-New Facility

Develop new and existing plastic process using scientific, decouple, optimize and enhance molding processes. RJG Master Molder I& II

Responsible for developing Work Instructions/SOP for new products and PPAP.

Working with PPAP and PFMEA by startup new products processes.

Works with all injection molding machines up to 3300 ton processing.

Use various virgin, regrind and regenerated materials to utilizing DOE and capability studies for data collection and evaluation of process optimization.

Responsible for supervising, training and mentoring technicians.

Integrate, set-up and qualify RJG system into online production automation to target 0% defect to customer.

Develop training, molding and safety for process technicians and operators

07/2015-03/2016 BOLTA US/Automotive TS16949 Tuscaloosa, AL USA

Injection Molding Manager

Green Field operation start up-New Facility

Manage and mentor group of 4 Engineers, 8 technicians, CMM tech

Manage up to 130 associates

Develop and implement departmental training plan

Works with customer and quality to solve quality issues. 8D, 5Y etc.

Final responsibility for process flow, equipment placement and overall structure and functionality of Molding Department

Oversees the development and implementation of molding PPAP protocol

Coordinates with all suppliers and contractors regarding development, installation and sign off of all molding equipment

Responsible for selecting and hiring entire molding department staff

Molding department start up thru TS16949 certification

Final hire/fire responsibility

02/2014-07/2015 SIO2 Medical Products/Medical ISO13485 Auburn, AL USA

Senior Validation Engineer-Injection Molding

Develop process for medical products using scientific molding (SIM) methodologies such as rheology studies, gate seal studies and DOEs

Extensive knowledge of all electric clean room molding machines

Validate processes and maintain documentation for PQ and OQ

Validate equipment and maintain documentation for IQ

Work with cGMP protocol such as record keeping and documentation

Use SIM studies to validate process parameters and define their operating windows

Work with high end automation for needle insertion to mold and downstream inspection

ISO13485 works in 100,000 class clean room

Develop DOE frame work for product validation

Work with and maintain Class A1 steel conditions to produce Class A surface

Lead molding team thru ISO13485 certification

02/2013-02/2014 North American Lighting/TS16949 Automotive Muscle Shoals, AL USA

Injection Molding Process-SR Process Engineer

Direct management group of 7 Process Engineers, 4 Master Techs, 24 Molding Tech and 30 molding associates

Ensures applied scientific molding methods are used for the development of all molding processes and related documentation.

Development of equipment and work cells associated to molding, including EOAT, Vision Systems and peripheral QA devices and ensures they are available for all new in house mold trials.

Analyzes CAE, Moldflow temperature and flow inside mold cavity

Directs process engineers thru APQP process and supporting data collection.

Developing and delivering tooling and process BOMs to manufacturing

Works with multi shot (co-injection) processes frequently

Work with customer to solve quality issues. 8D, 5Y etc.

Frequent customer and supplier interaction on various levels

Extensive use of all Microsoft Office products for multiple purposes including customer presentations. SolidWorks, CAD data.

07/2008-02/2013 Electricfil Sensors/TS16949 Automotive Athens, AL USA

Molding Technology Leader

New and existing plastic process using scientific, decouple, optimize and enhance molding processes.

Sources and validates for new tooling suppliers (Domestic and Asian).

Development of Functional Specifications, BOMs and other documents which direct suppliers in the construction of Electricfil Tooling.

Communicating dimensional requirements, steel changes, revisions, functional specs and general design requirements with European, Asian and domestic tooling suppliers

Recommend materials suitable for the manufacturing of Electricfil products.

Review 2D and 3D part designs and tool designs and Mold flow simulations to validate engineering studies for all new molded products-GD&T

01/2007-07/2008 Nypro/Custom Molder Dothan, AL USA

Senior Process/Project Engineer

Communicate project milestones, goals and obstacles with internal and external team members

Responsible for internal transfer projects dealing with transfer of existing tooling and work cells from other Nypro facilities.

Develop start-up, shutdown, material handling, Lockout tag out and other procedures related to individual process and project.

Designing material/process flow layouts and work cell layouts.

Decouple, optimize and enhance existing molding processes and develop production processes utilizing DOE and capability

Corporate injection molding trainer for all Nypro facilities-RJG Master Molder II

Responsible for supervising, training and mentoring 16 technicians as direct reports.

Develop training and molding safety programs for process technicians and operators targeted at enhancing plant wide technical capability.

Trouble shoot process, tooling and IMM problems

08/2004-01/2007 Nexpak/Media Packaging Helmond,Netherlands

Project Manager/Manufacturing Manager/Senior Process Engineer

Relocated to Netherlands and start up Sony project

Responsible for supervising, mentoring and training 12 technicians as direct reports.

Project Management role with the ability to track and control resources, timelines and project capital.

Extensive knowledge concerning processing hot runner tools with manifold/drop systems made by Manner and Mitsubishi.

Extensive processing experience with tooling utilizing valve gate control

Responsible for selection of IMMs and peripheral equipment utilized such as material handling layout, workstation set-up and process flow layout

Responsible for all prototype and production tool trials and debugs. Responsible for facility including a 10,000 class clean room.

Develop Work Instructions/SOP for new products and processes.

01/2001-08/2004 Smith Tech Inc./Injection Molding Service Engineer Greenville, Sc. USA

CEO/Engineer/Service Engineer

Coordinating and managing all aspects of a service-based business

Offer injection molding tooling, process and equipment optimization on service level.

Providing technical and processing assistance to injection molding companies such as Ciba Vision, Classic Lab Equipment, Vistakon and J&J and IMM machine manufactures across the United States and abroad.

Provide technical training for processing, controls and tooling to customer staff.

Represented IMM manufactures including Sumitomo, Engel, Demag, Toshiba, Nissei, JSW, Kraussmaffei and Van Dorn from 25 to 2500 tons.

12/2000-01/2001 Netstal Machinery/IMM Devens, Ma. USA

Service Engineer-Injection Molding

Installing, trouble-shooting and repairing Disc Jets, Synergy and the rest of Netstal’s product line.

I have extensive experience with optical disk and polycarbonate processing. A large part of my duties involved starting-up and processing new CD and DVD line

I have specialized training for the processing, maintenance and troubleshooting of two component, co-injection machines.

05/1992-12/2000 Sumitomo Plastic IMM Manufacturer Norcross, Ga. USA

Service Engineer-Injection Molding

Installing, trouble-shooting and repairing all machines in the Sumitomo product line.

Responsible for all mold trials, in house and at customer site

Worked directly with customers, such as Fuji Photo Film, JVC Disc, Sony Music, Ciba Vision, TDK and Mitsui providing processing and technical training, repair, troubleshooting and a variety of other customer support functions.

Gained extensive knowledge of all electric machines.

Performed all types of calibration including PID, parallelism and precision leveling to all types of machines.


ABS, PC, PC/ABS, PA66 5-50 GFI, PPS, Xtel Alloy, POM, PC, LDPE, HDPE, PP, PBT, TPE, COP, COC, TPU, ASA-Thermoplastic and Thermoset


50-3000 Ton Machines-Sumitomo, Nissei, Netstal, RoboShot, Krauss Maffei, Arburg, Battenfeld, Engel, UBE, Husky, Milacron, Ferromatik, Van Dorn

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