- Location: Sparta , Tennessee
- Type: Direct Hire
- Job #11683
- Salary: $110,000 - $130,000
Location Type: On-Site
We are seeking an experienced Senior Processing Engineer to serve as a technical leader within our plastics manufacturing operation. This position is responsible for developing, optimizing, and supporting manufacturing processes for injection molding, blow molding, and reheat stretch blow molding operations. The ideal candidate will possess extensive hands-on experience processing PET, PP, and HDPE materials and demonstrate a strong ability to improve manufacturing performance through process optimization, troubleshooting, and continuous improvement initiatives.
Working closely with Operations, Quality, Maintenance, Engineering, and Product Development teams, the Senior Processing Engineer will play a critical role in driving productivity, improving product quality, reducing waste, and supporting new product launches.
- Develop, validate, and optimize manufacturing processes for injection molding, blow molding, and reheat stretch blow molding equipment.
- Improve cycle times, machine efficiencies, scrap reduction, and overall equipment performance.
- Establish and maintain optimum processing parameters for new and existing products.
- Evaluate production data to identify opportunities for increased throughput and cost savings.
- Lead the diagnosis and resolution of complex processing issues affecting safety, quality, productivity, or equipment performance.
- Utilize structured problem-solving techniques including Root Cause Analysis (RCA), 5 Why, Fishbone, and corrective/preventive actions.
- Provide technical support to production during startup, changeovers, and process interruptions.
- Support new product introductions by developing robust manufacturing processes that meet design, quality, and production requirements.
- Partner with Engineering, R&D, Tooling, and Production teams during product development and commercialization.
- Validate tooling, equipment, and process capability prior to production release.
- Collaborate with Maintenance and Engineering to maximize molding equipment reliability and process capability.
- Assist with equipment selection, installation, startup, and qualification of new machinery.
- Recommend equipment upgrades and process improvements to improve operational performance.
- Work closely with Quality to ensure products consistently meet customer specifications and regulatory requirements.
- Develop standardized processing parameters, work instructions, and process control documentation.
- Monitor process capability and implement corrective actions to improve consistency and reduce variation.
- Lead continuous improvement initiatives focused on safety, quality, productivity, and cost reduction.
- Apply Lean Manufacturing, Six Sigma, and other operational excellence methodologies to eliminate waste and improve manufacturing performance.
- Participate in Kaizen events and cross-functional improvement projects.
- Maintain accurate processing documentation including setup sheets, process parameters, standard operating procedures, and engineering records.
- Track and analyze key process metrics to support data-driven decision making.
- Prepare technical reports and presentations for leadership as required.
- Serve as a technical mentor for Process Technicians, Operators, and junior engineering staff.
- Develop and deliver training on processing techniques, troubleshooting, equipment operation, and best practices.
- Promote a culture of technical excellence, safety, and continuous learning throughout the manufacturing team.
- Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, Plastics Engineering, or a related technical field preferred.
- 8+ years of hands-on plastics processing experience in a manufacturing environment.
- Extensive experience with:
- Injection Molding
- Blow Molding
- Reheat Stretch Blow Molding
- Strong knowledge of processing:
- PET
- Polypropylene (PP)
- High-Density Polyethylene (HDPE)
- Proven experience optimizing molding processes to improve quality, efficiency, and production performance.
- Strong analytical, troubleshooting, and problem-solving skills.
- Excellent communication skills with the ability to work effectively across Engineering, Production, Quality, and Maintenance teams.
- Proficiency with manufacturing process documentation and data analysis.
- Experience with Lean Manufacturing, Six Sigma, Kaizen, or other continuous improvement methodologies.
- Knowledge of statistical process control (SPC) and process capability analysis.
- Experience supporting capital equipment installations and validation projects.
- Master Molder Certification or willingness to obtain certification within 18–24 months of employment.
- Primarily based in a manufacturing environment with regular exposure to production equipment and industrial machinery.
- Combination of production floor and office work.
- Ability to stand, walk, and inspect equipment for extended periods.
- Occasional travel may be required to support training, equipment installations, or collaboration with other manufacturing facilities.
