Job Description

Job purpose

The Injection Molding Process Technician is responsible for setting up, starting, monitoring, troubleshooting, and optimizing nine injection molding machines. All nine machines are equipped with RJG eDART process monitoring systems and utilize cavity pressure for transfer from injection (fill) to pack/hold.

This position is responsible for maintaining stable, repeatable molding processes using cavity pressure data, ensuring consistent part quality, minimizing downtime and scrap, and achieving production targets. The technician must be proficient in interpreting cavity pressure curves, monitoring process limits, troubleshooting molding defects, and maintaining approved process parameters.

The successful candidate will take ownership of the assigned molding area, ensuring all nine machines operate safely, efficiently, and consistently while meeting quality requirements and production schedules.

Duties and responsibilities

• A. Machine Setup and Process Control
• Set up, start, adjust, and optimize injection molding machines according to approved setup sheets and process specifications.
• Perform mold changes, material changes, color changes, and production changeovers.
• Establish and maintain approved process parameters, including injection speed, pressure, barrel temperatures, mold temperatures, cooling time, pack/hold settings, and cycle time.
• Set up and verify cavity-pressure-based transfer from injection to pack/hold according to established process requirements.
• Ensure transfer is controlled by the approved cavity pressure setpoint or pressure-based transfer criteria rather than relying solely on screw position or elapsed time.
• Verify that machine settings, cavity pressure profiles, and process limits are consistent with the approved process.
• Monitor all nine assigned machines to ensure stable production and consistent part quality.
• Perform startup checks, first-piece inspections, and process verification before releasing machines for production.
• Document approved process settings and ensure changes are made only within authorized limits.
• B. RJG eDART and Cavity Pressure Process Monitoring
• Operate, monitor, and troubleshoot RJG eDART process monitoring systems installed on all nine injection molding machines.
• Interpret cavity pressure curves to evaluate process stability, transfer performance, packing behavior, and overall molding consistency.
• Monitor cavity pressure at transfer, peak cavity pressure, pressure rise, curve shape, and other established process indicators.
• Verify that cavity pressure-based transfer is functioning correctly and consistently on each machine.
• Monitor eDART alarms, process limits, and out-of-specification conditions and respond according to established procedures.
• Identify abnormal pressure profiles and investigate potential causes, including material variation, mold conditions, blocked or damaged sensors, machine performance, and process settings.
• Recognize changes in cavity pressure signatures that may indicate short shots, flash, dimensional variation, sink, warpage, or other quality concerns.
• Verify that cavity pressure sensors and monitoring channels are functioning properly and that the correct signals are associated with the applicable mold cavities.
• Maintain approved cavity pressure profiles, process windows, transfer criteria, and alarm limits.
• Use eDART process data to support troubleshooting, root-cause analysis, process validation, and continuous improvement.
• Work with Quality, Engineering, Maintenance, and RJG technical support when advanced troubleshooting or process development is required.
• Ensure process monitoring data is used proactively to identify variation before it results in excessive scrap or customer quality issues.
• C. Troubleshooting and Process Optimization
• Identify and correct molding defects, including short shots, flash, sink marks, warpage, burn marks, splay, contamination, and dimensional defects.
• Troubleshoot machine, mold, material, auxiliary equipment, and process-related problems.
• Use cavity pressure profiles and eDART data to determine whether process abnormalities originate from the machine, mold, material, sensors, or process settings.
• Optimize cycle times while maintaining approved cavity pressure profiles and part quality.
• Identify opportunities to reduce scrap, improve process repeatability, increase machine uptime, and improve overall equipment effectiveness (OEE).
• Perform root-cause analysis for recurring defects, downtime, and process variation.
• Implement corrective actions within approved process parameters and document significant adjustments.
• Coordinate with Maintenance, Tooling, and Engineering to resolve recurring mechanical, electrical, tooling, or process issues.
• D. Production Oversight
• Maintain awareness of production status, cycle times, machine performance, and job priorities across all nine machines.
• Prioritize machine checks and troubleshooting based on production needs, alarms, process deviations, and quality risks.
• Monitor machine alarms, cycle interruptions, downtime, and production rates.
• Respond promptly to machine stoppages, eDART alarms, process deviations, and quality concerns.
• Coordinate with production operators to ensure adequate material supply, correct packaging, and proper part handling.
• Communicate machine status, production delays, and unresolved issues to the Production Manager or appropriate personnel.
• Provide clear shift handoff information covering machine status, process concerns, downtime, and outstanding corrective actions.
• Support production scheduling, mold changeovers, and startup activities as required.
• E. Quality Assurance
• Ensure molded parts meet established dimensional, visual, and functional requirements.
• Perform or support first-piece inspections and required in-process quality checks.
• Verify that the correct resin, colorant, mold, and approved process specifications are being used.
• Use cavity pressure monitoring and established process limits to help maintain consistent part quality.
• Identify, contain, and segregate nonconforming material and notify Quality when necessary.
• Ensure process deviations are investigated and corrected before production resumes when required by established procedures.
• Complete inspection records, process documentation, and production paperwork accurately.
• Support quality investigations, corrective actions, process validation, and continuous improvement initiatives.
• F. Materials and Auxiliary Equipment
• Verify material requirements before production begins.
• Ensure proper resin drying, handling, blending, and loading according to material specifications.
• Monitor dryers, material loaders, temperature controllers, mold temperature units, water lines, and other auxiliary equipment.
• Prevent material mix-ups, contamination, and incorrect material usage.
• Identify material-related process variation and investigate its impact on cavity pressure profiles and part quality.
• Coordinate with appropriate personnel to correct material supply and auxiliary equipment issues.

Qualifications

• High school diploma or GED required; technical training in plastics processing or manufacturing preferred.
• Minimum of three years of injection molding experience preferred, including machine setup, processing, and troubleshooting.
• Demonstrated ability to independently set up, process, and troubleshoot injection molding machines.
• Hands-on experience with RJG eDART systems and cavity pressure monitoring required.
• Demonstrated understanding of cavity-pressure-based transfer from injection to pack/hold required.
• Ability to interpret cavity pressure curves and identify process deviations.
• Knowledge of injection molding defects, process variables, and corrective actions.
• Experience with mold changes, resin changes, dryers, material loaders, temperature controllers, and auxiliary equipment.
• Ability to read and follow setup sheets, work instructions, control plans, and quality specifications.
• Basic computer skills for process documentation, production reporting, and data review.
• Strong mechanical aptitude, troubleshooting ability, attention to detail, and problem-solving skills.
• Ability to manage priorities and respond effectively to issues across nine machines.
• Ability to work independently while communicating effectively with production and support teams.

Language Skills

Must speak English

Mathematical Skills

• Proficiency in addition, subtraction, multiplication, and division.
• Understanding different units of measurements (such as inches, millimeters, decimals etc.)

**Reasoning Ability **

• Ability to apply common sense and understanding to carry out detailed but uninvolved written or oral instructions
• Ability to deal with problems involving a few concrete variables in standardized situations

**Computer Skills **

• Proficiency in Microsoft Office Suite.
• Ability to use power point for presentations and training purposes.
• Experience using Excel for data analysis, tracking production metrics, data entry, and creating reports.
• Microsoft Word for document creation and report writing.
• Microsoft Teams.
• SAP experience a plus.

You should be proficient in:

• Injection Cavity Pressure Monioring
• Injection Molding Systems
• Injection Molds and Dies
• Injection Molding Equipment Operations