Job Summary:The Process Specialist is responsible for developing and improving industrial processes to enhance efficiency, reduce costs, improve sustainability, and maximize profitability. This role ensures that products are manufactured to the highest quality standards using cost-effective methods while maintaining safety and maximizing productivity to achieve plant goals.Key Responsibilities:1. Process Optimization:
- Optimize machine processes by reducing scrap, cycle times, and mold change times.
- Implement scientific molding, process monitoring, and tool qualifications.
- Develop and execute DOE studies for process improvements, recommending tooling adjustments when necessary.
- Lead process improvement initiatives for the molding team, including cycle time reduction, material conversion, and statistical capability improvements.
- Lead implementation of standardized molding process limits using data analysis to improve control and eliminate defective products.
2. Tooling & Equipment:
- Lead all new tooling qualifications by establishing and documenting robust molding process parameters.
- Provide input for new project quotes to ensure planned equipment is suitable (e.g., core pulls, clamp tonnage).
- Review and critique mold vendor design proposals to ensure functional mold performance, including Moldflow analysis.
- Conduct injection molding, downtime, and utilization studies to determine overall equipment effectiveness.
3. Program Launch Support:
- Assist with new program launches by building processes to ensure quality parts.
- Attend New Model tooling trials to identify potential production issues before plant operations begin.
- Support Engineering with part design, tool design, prototyping, mold sampling/approval, and lead dimensional reconciliation processes.
4. Problem Solving & Cost Efficiency:
- Lead problem-solving efforts for root cause determination of part defects.
- Propose and evaluate cost-saving measures related to molding.
- Implement process and quality improvements through lean and continuous improvement methods.
5. Training & Development:
- Provide on-the-job training to technical teams, including Process Setup and Material Handlers.
- Create and maintain Work Instructions for Molding best practices.
6. Collaboration & Communication:
- Work closely with the tooling team for mold evaluations and recommendations.
- Collaborate with maintenance to address machine issues.
- Lead cross-functional team activities to identify top issues and implement corrective actions.
- Interact with customers, suppliers, and internal resources to ensure smooth operations.
7. Additional Responsibilities:
- Enforce all company policies and procedures, promoting a safety-first culture.
- Maintain a clean and organized work area with emphasis on safety, quality, and productivity.
- Support plant standards and the 5S system.
- Assist with SMED activities to improve changeover times.
Qualifications:Experience:
- 5+ years in an Injection Plastics Molding environment with comprehensive knowledge of plant manufacturing equipment.
- Minimum of 5 years in injection molding engineering/processing roles.
- Experience with direct/indirect leadership of process technicians (an asset).
Technical Skills:
- Proficiency in Microsoft Office (Excel, PowerPoint, Word, Outlook).
- Strong knowledge of plastics technology, including screws & barrels, molding material delivery systems, temperature control units, grinders, and dryers.
- In-depth understanding of Scientific Injection Molding and RJG principles.
Communication & Interpersonal Skills:
- Excellent communication and interpersonal skills with leadership capability in a team environment.
- Strong written and verbal communication, interpersonal, and motivational skills.
Other Skills:
- Ability to inspire and cultivate a team by establishing trust and engaging on the floor.
- Strong attention to detail with a commitment to thorough completion of work tasks.
- Experience in the Automotive industry is an asset.
- Knowledge of health and safety practices in a plant environment.
Reporting Hierarchy:
- Reports to: Plant Manager
Working Conditions:
- Factory/manufacturing fast-paced environment.
- Safety shoes and glasses required.
- Day shift with flexibility to assist on off-shift when required.
- Own toolbox with tools and testing equipment.
- Some travel may be required for tooling trials.
Physical Requirements:
- Ability to lift up to 50 lbs.
- Ability to reach, bend, stoop, and climb as necessary.