Blow Molding Process Optimization Engineer

Shape the process. Elevate the product.

As a Blow Molding Process Optimization Engineer, you’ll be the point person for modernizing and stabilizing production across our plastic manufacturing operations. Your day might begin on the floor validating Standard Operating Conditions (SOC) ranges, move into a Kaizen workshop with OPEX to cut cycle time, and finish with a targeted troubleshooting session that reduces variability and scrap. You will partner closely with Plant Managers, Process Technicians, operators, Reliability and Quality teams to build a robust, repeatable process foundation across multiple facilities.

Location

Preferred: Alsip, Illinois. Alternate: Houston, Texas.

What you’ll drive day-to-day

• Lead process improvement using Lean tools (Kaizen, VSM, A3) focused on productivity, labor optimization, quality, and waste reduction—then scale wins across plants.
• Plan and execute process optimization trials; analyze results; set optimal parameters to meet certification and performance requirements.
• Evaluate existing equipment and controls for throughput, cost-efficiency, and safety; prepare equipment/controls specifications and place orders for upgrades or replacements.
• Apply root cause analysis and structured problem-solving to eliminate recurring issues.
• Create, maintain, and enforce SOCs with min/max ranges for all major assets.
• Partner with maintenance to establish and audit a Critical Process Equipment (CPE) program; ensure assets are documented and well-maintained.
• Collaborate with Reliability Engineering and Quality to deploy full VQS on each machine.
• Standardize best practices, replicate lessons learned, and elevate process capability across sites.
• Develop and deliver training for operators, maintenance, and plant leaders; build comprehensive process-related training materials.
• Work closely with Product Engineering on trials, prototypes, samples, and new product introductions impacting process windows.
• Maintain thorough records of trials, SOCs, and changes; prepare monthly quality and production reports.

Must-have background

• Bachelor’s degree (or equivalent) required.
• 5+ years of experience in plastic blow molding is required.

Technical toolkit and competencies

• Hands-on skill with electrical, pneumatics, hydraulics, air compressors, chillers, and PLCs; able to adjust controls and parameters confidently.
• Proven ability to troubleshoot complex machine issues and optimize cycle times for cost savings.
• Strong Lean/Continuous Improvement orientation.
• Deep understanding of plastics materials, blow molding processes, and machinery operation.
• Meticulous approach to quality assurance and documentation; strong MS Office proficiency.
• Clear communicator and effective collaborator across cross-functional teams.
• Strict adherence to safety practices in manufacturing environments.
• Ability to implement process changes that consistently achieve high-quality output.
• Ability and willingness to travel required.

Compensation

The pay range for this position is $101,800.00 - $173,300.00. Typically, a competitive wage for new hires will fall between $125,000.00 to $135,000.00. Offers for this position may vary based on market data and other factors such as job-related knowledge, skills, experience, and geographic location. The position may also be eligible for a short-term incentive.

You should be proficient in

• Mechanical Troubleshooting Skills
• Pneumatics Experience
• Process Engineering
• PLC Programming Experience
• Lean Manufacturing Principles
• Engineering Degree
• Plastic Extrusion Experience
• Blow Molding Experience

Machines & technologies you’ll use

• Extrusion Machine
• ERP Software
• Blow Molding Machine