Senior Process Engineer

Based in Mukwonago, Wisconsin, this on-site role at Milwaukee Electric Tool Corporation centers on leading injection molding process development, optimization, and long-term sustainment. The Senior Process Engineer applies data-driven decision-making, advanced process control, and continuous improvement to elevate manufacturing performance in a demanding plastics environment.

Responsibilities

• Develop, optimize, and sustain injection molding processes using scientific molding principles to achieve quality, delivery, and cost targets.
• Define and validate robust process windows, control strategies, and safeguards using DOE, Cp/Cpk, and statistical methods.
• Support tooling lifecycle activities, including design reviews, build validations (T0/T1/Tn), and continuous process/tooling improvements.
• Drive root cause analysis and corrective/preventive actions for molding-related defects, leveraging data to eliminate systemic issues.
• Partner cross-functionally with design, tooling, quality, and operations to ensure manufacturability and performance targets are met.
• Identify trends through process and quality data to drive continuous improvement and defect reduction initiatives.
• Create and maintain standardized process documentation (SOPs, control plans) to ensure repeatability and scalability.
• Provide technical leadership, training, and support to manufacturing teams to strengthen process capability and execution.

Requirements

• BS in Plastics Engineering Technology or equivalent
• 5+ years of hands-on thermoplastics processing experience.
• RJG Master Molder I/II strongly preferred.
• Demonstrated expertise in scientific molding, process validation, and process troubleshooting.
• Strong understanding of mold design, tooling principles, material data, molding machines, auxiliaries, and process monitoring tools.
• Robotic programming and troubleshooting required.
• Strong problem-solving skills (A3 / 5 Why / 8D) and attention to detail are essential.
• Preferred proficiency in CAD/CAE
• Great to have Six Sigma Yellow or Green belt.

Technologies

• CAD/CAE
• Robotic programming
• RJG Master Molder I/II