Position Summary

The FIP Injection Molding Engineer plays a critical role in the development, optimization, and ongoing support of foam-in-place (FIP) injection molding processes for automotive components. This position leverages expertise in materials, process engineering, and equipment performance to ensure high-quality production, efficient operations, and continuous improvement across manufacturing operations.

Qualifications (Knowledge, Skills, and Abilities)

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Chemical Engineering, or a related field
• Minimum of 3 years of experience in foam-in-place or injection molding processes, preferably within the automotive industry
• Strong understanding of polymer materials, mold validation, and process control methodologies
• Proficiency in CAD software (e.g., SolidWorks, AutoCAD) and data analysis tools (e.g., Minitab, Excel)
• Familiarity with automotive quality systems and standards, including APQP, PPAP, and IATF 16949
• Excellent problem-solving, communication, and project management skills
• Ability to thrive in a fast-paced, collaborative manufacturing environment

Primary Responsibilities

• Develop, optimize, and stabilize foam-in-place injection molding processes to improve cycle times, reduce scrap, and enhance product quality
• Provide hands-on engineering support to production teams, including troubleshooting complex process issues and implementing corrective and preventive actions
• Collaborate with tooling engineers and external suppliers to validate molds, fixtures, and auxiliary equipment
• Evaluate and specify foam materials and resins; partner with suppliers to qualify new materials and ensure compatibility with process requirements
• Apply statistical tools (SPC, DOE, Six Sigma) to analyze process data and drive continuous improvement initiatives
• Create, maintain, and update process documentation, including work instructions, PFMEAs, control plans, and validation protocols
• Partner with quality and production teams to ensure manufacturability and compliance with automotive standards (e.g., IATF 16949)
• Lead or support engineering projects such as new product launches, equipment upgrades, and process transfers

Essential Job Requirements

• Monitor and analyze production and process data to identify trends, risks, and improvement opportunities
• Provide technical guidance and support to production personnel
• Conduct root cause analysis for process deviations and implement sustainable corrective actions
• Coordinate with maintenance and automation teams to ensure equipment reliability and uptime
• Maintain accurate engineering documentation and update process standards as required

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