Process Engineer in Auburn Hills, Michigan at Amaneos US, Inc.

Position Summary:
Process Engineer is responsible for developing, optimizing, and sustaining injection molding processes used in the production of automotive components. This role focuses on new tool development, process development, continuous improvement, product launches, quality enhancement, and cost reduction initiatives. The engineer works closely with product engineering, tooling suppliers, manufacturing, quality, maintenance, and customers to ensure robust and efficient production processes that meet automotive quality standards.

Duties and Responsibilities:
Develop, validate, and optimize plastic injection molding processes for new and existing automotive products.
Establish process parameters, process windows, and standard operating procedures (SOPs).
Conduct Design of Experiments (DOE) to improve process capability and product quality.
Perform process characterization studies to achieve stable and repeatable manufacturing processes.
Analyze molding data and implement corrective actions to improve cycle times, reduce scrap, and increase productivity.
Support process capability studies (Cp, Cpk) and Statistical Process Control (SPC) implementation.
Lead technical activities related to new mold development from concept through production launch.
Review part designs for manufacturability (DFM) and provide recommendations for tooling and process improvements.
Collaborate with toolmakers and suppliers during mold design, construction, and validation phases.
Participate in mold flow analysis reviews and recommend design modifications.
Manage mold trials, tool qualifications, capability studies, and production readiness activities.
Reduce cycle times, material consumption, labor requirements, and overall manufacturing costs.
Implement automation solutions and process monitoring technologies to improve efficiency.
Lead root cause analysis activities using methodologies such as 8D, 5 Why, and Fishbone Analysis.
Identify and implement best practices across molding operations.

Preferred Education and Skills:
Bachelor’s degree in plastic engineering or related field of study. Alternatively, 12 years’ equivalent experience in molding and manufacturing technologies. Expertise in injection molding process setup, optimization, and troubleshooting.
Knowledge of mold flow analysis software (Moldflow, Moldex3D, or equivalent).
Experience with DOE, SPC, MSA, PFMEA, and Control Plans.
Understanding of APQP, PPAP, IATF 16949, and AIAG Core Tools
RJG Master Molder certification or equivalent.
Scientific molding experience.