Summary of Position

Senior Project Engineer is responsible for being the complete source of information for all assigned projects. Works closely with other departments to ensure that customers receive quality products on time. Responsible for the development of injection molded components and assemblies utilizing DFMA (Design for Manufacturing & Assembly) principles, sound engineering skills, and other engineering tools. Contributes to the maintenance of a safe, productive manufacturing environment through product and process design. Ensures that assigned projects meet the Company’s financial objectives. Ensures that all work activities are in compliance with the appropriate ISO 9001 procedures. Mentors/trains less experienced engineers in plastic materials, tooling, processing, simulation, and project management. May have one or more direct reports in the role of engineer or engineering assistant. Finds and implements improvement opportunities at the engineering or organizational level.

Essential Duties, Responsibilities, & Authority

• Prepares accurate part quotations based on customer design and quality criteria, the manufacturing process involved, and Company pricing objectives.
• Owns cross-functional projects to ensure that financial, timing, and quality objectives for selected projects are met.
• Reviews tooling specifications and quotations for conformance to design, quality, manufacturing, and pricing objectives.
• Designs or oversees the design of products/components using both creativity and sound engineering practices. Prepares sketches, computer-generated images and detailed drawings to effectively communicate design intent to the customer, toolmaker, or CAD designer. Communicates with and travels to the customer and toolmaker as required to ensure all aesthetic and functional parameters are met.
• Runs injection molding simulations to optimize part design, tooling, and processing. Communicates results to the processing team and helps develop solutions to processing issues.
• Prepares and updates project schedules for use by the customer, suppliers, and the internal core team. Ensures scheduled dates are met. Periodically advises customer of project status.
• Monitors product/project costs throughout the design and early production stage. Recommends necessary actions to maintain project margin objectives.
• Leads FMEA (Failure Modes and Effects Analysis) reviews and documents required action items and due dates for completion.
• Designs product packaging to provide safe transport and ease of manufacturing while minimizing cost and environmental impact.
• Accurately and in a timely manner prepares ERP Master Data (Bills of Materials, Routings, Production Versions, Packing Instructions), requests purchase orders, calls design review meetings, and completes all other necessary paperwork per the product development process.
• Responsible for molded sample analysis for conformance to design and quality specifications. Submits samples for customer approval. Completes inspection reports and updates drawings accurately and in a timely manner. Requests process capabilities as needed.
• Periodically reviews production processes against ERP Master Data. Takes prompt action to correct discrepancies.
• Assists in establishing quality standards with the customer, manufacturing, quality, and sales.
• Assists in the resolution of production issues such as high scrap levels, quality non-conformances, etc. Evaluates alternate materials for product/process improvements. Recommends cost reductions and/or quality enhancements proactively.
• Contracts outside services (models, material analysis, first article inspection, etc.) as necessary. Seeks out and evaluates new suppliers as needed.
• Holds overall responsibility for the functioning, training, and maintenance of a project engineering technical system. Examples of technical systems include 3D CAD, Moldflow, etc.
• Assists and trains project engineers as needed.
• Contributes to a creative knowledge environment through the exchange of information with others. Assists in the training of engineering technical assistants. Maintains a clean, orderly, and productive work environment to foster personal and professional growth for both the individual and the company.
• Learns, practices, and supports all Lean Manufacturing tools to assist the company in the continuous improvement process.
• Promotes actions in accordance with the company’s core values by leading through example.
• Constantly looking for continuous improvement opportunities at all levels of the organization.
• Follows Sussex IM’s environmental policies to protect and minimize our impact on the environment.
• Maintains a safe 5S working environment to minimize the possibility of an injury. Acts in a safe manner at all times and ensures that those around them do not put themselves or others at risk. Reports any unsafe conditions to a manager.
• Performs other related duties and assignments as assigned or required.

Required Education, Credentials, & Certifications

• Bachelor’s degree in engineering or a similar technical field.

Job Specification

• Minimum 10 years of engineering experience in injection molding

Knowledge, Skills & Abilities

• Knowledge of new product development processes and best practices.
• Experience with injection molding simulation and optimization.
• Proficiency in injection molding including materials, processing, tooling, and part design.
• Proficiency in project management practices.
• Uses good interpersonal communication techniques to work with subordinates and/or co-workers. Is courteous and helpful when interacting with fellow employees. Attends available interpersonal skills training courses. Helps to create a pleasant work environment.
• Proficiency in mathematics and/or statistics and problem-solving.
• Good technical writing skills and verbal communication skills.
• Ownership of projects and outcomes.
• Attention to detail.
• Displays a good sense of urgency.
• Demonstrates accuracy and thoroughness and monitors own work to ensure quality.
• Ability to coach, mentor, and motivate.
• Proclivity towards challenging the status quo.