Process Technician (Injection Molding) 3rd Shift 11 PM-7:30 AM in New Castle, Delaware at Zenith Home Corp

Position Summary

The Setup & Process Technician is responsible for mold setups, process optimization, troubleshooting, and maintaining stable injection molding operations to meet production, quality, and safety targets. This role applies advanced technical skills and hands-on work to ensure efficient machine performance and product consistency.

This position is classified as non-exempt under the Fair Labor Standards Act because the primary duties involve skilled technical and manual work supporting production operations rather than management or professional exempt duties.

Essential Duties & Responsibilities

Setup & Process Technician – Injection Molding

Machine Setup & Changeovers

• Perform safe and efficient mold installations, removals, and startups.
• Connect and verify all required utilities, including water, hydraulics, pneumatics, and auxiliaries.
• Set up and validate dryers, blenders, robots, hot runners, and temperature controllers.
• Complete material verification and line clearance prior to production.
• Execute changeovers in accordance with SMED and lean manufacturing principles.
• Continuously seek opportunities to reduce setup time and improve efficiency.

Process Development & Optimization

• Establish, document, and maintain robust processing parameters.
• Develop and update standard process sheets and setup documentation.
• Monitor cycle time, scrap, downtime, and overall equipment effectiveness (OEE).
• Optimize temperature, pressure, speed, and timing for stable, repeatable production.
• Support mold trials, validation runs, and process capability studies (Cp/Cpk).
• Lead troubleshooting efforts for molding defects including short shots, flash, splay, burns, warpage, and dimensional variation.
• Implement continuous improvement initiatives to improve quality and productivity.

Production Support & Troubleshooting

• Respond promptly to machine alarms, quality issues, and production interruptions.
• Diagnose and resolve mechanical, electrical, hydraulic, and process-related problems.
• Partner with Maintenance, Engineering, and Quality to resolve recurring issues.
• Provide on-floor technical support to operators and production staff.
• Train operators on proper startup, shutdown, and process monitoring procedures.
• Ensure production runs meet established quality, safety, and delivery requirements.

Quality & Documentation

• Follow all safety, environmental, and regulatory requirements.
• Ensure compliance with work instructions, control plans, and quality standards.
• Support PPAP, audits, and customer requirements as needed.
• Maintain accurate production, process, and setup documentation.
• Promote a culture of safety, accountability, and continuous improvement.

Safety & Workplace Practices

• Follow lockout/tagout procedures and machine safety requirements.
• Maintain organized and safe work areas.
• Identify opportunities to improve safety and efficiency.

Mayzon offers a competitive health care benefits package, a 401(k) plan, paid vacations and holidays, employee discounts, among other fringe benefits.

Required Qualifications

• High school diploma or equivalent required.
• 3+ years of injection molding setup and processing experience.
• Strong knowledge of plastics materials and molding parameters.
• Ability to read mechanical drawings and electrical schematics.
• Experience troubleshooting molding defects and machine issues.
• Ability to use hand tools, measurement tools, and process documentation.