Plastics Process Engineer

Role details

Leviat is a global leader in insulating, lifting, anchoring, and connecting technology for the construction industry and is home to trusted product brands like Meadow Burke, Halfen, and Thermomass. Our engineered products and innovative solutions are used in projects of all sizes, from single-family homes to professional sports arenas.

Leviat employs nearly 3,000 people at 60 locations worldwide, including seven in the United States. We are committed to an inclusive work environment that prioritizes safety and fosters personal and professional growth.

Job Description Summary

Leviat is seeking a Plastics Process Engineer to oversee the optimization, maintenance, and production standards used in our plastic manufacturing processes to ensure product quality, production efficiency, safety, and cost effectiveness. This role supports operations by troubleshooting process issues, leading continuous improvement initiatives, and implementing new technologies and manufacturing methods for injection molding or other plastics processing operations. This position will work closely with all levels of management and employees to ensure safety and promote our safety culture.

Essential Duties

• Troubleshoot molding and processing issues related to machines, tooling, materials, and equipment.

• Establish and maintain process parameters, standard operating procedures, and work instructions.

• Lead process validation activities and capability studies where applicable.

• Analyze production data and identify opportunities for waste reduction, cycle time improvements, and cost savings.

• Support new product launches through tooling trials, process development, and production ramp-up activities.

• Collaborate with Quality, Manufacturing, Maintenance, Tooling, and Supply Chain teams to resolve operational issues.

• Conduct root cause analyses and implement corrective and preventive actions.

• Evaluate and recommend new equipment, tooling, materials, and automation technologies.

• Keeps equipment operational by coordinating maintenance and repair services; following manufacturer's instructions and established procedures; requesting special service.

• Completes design and development projects by training and guiding technicians.

• Develop and implement process improvements to optimize product quality, production efficiency, and cost.

• Troubleshoot and resolve process issues to minimize downtime and maintain production targets.

• Lead installation, startup, and qualification of new molding or plastics processing equipment.

• Support automation integration, including robotics, conveyors, vision systems, and downstream equipment.

• Drive ramp-up activities to achieve targeted safety, quality, throughput, and OEE objectives.

• Review mold designs and provide Design for Manufacturability (DFM) recommendations.

• Lead tooling improvement projects to enhance cycle times, part quality, reliability, and mold maintenance intervals.

• Evaluate alternative resins, additives, colorants, and recycled materials to reduce part cost while maintaining product requirements.

• Lead material qualification and validation projects, including testing for mechanical, thermal, and cosmetic performance.

• Identify opportunities for resin down-gauging, regrind utilization, and material substitutions

• Ensure compliance with safety, environmental, and quality standards.

• Train production personnel on process controls, operating procedures, and best practices.

• Participate in continuous improvement initiatives using Lean Manufacturing and Six Sigma methodologies.

• Monitor and improve Overall Equipment Effectiveness (OEE), scrap rates, and productivity metrics.

• Perform other duties as assigned.

Required Skills / Qualifications

• Bachelor's degree in Plastics Engineering, Chemical Engineering, Mechanical Engineering, Manufacturing Engineering, or related field preferred.
• 3+ years of experience in plastics manufacturing and process engineering.
• Strong knowledge of plastic materials, resins, and processing techniques.
• Experience with one or more of the following injection molding.
• Injection molding

• Knowledge of automation, robotics, and vision systems.

• Proficiency in statistical analysis, process capability studies, and root cause problem solving.
• Experience with manufacturing ERP systems and data analysis tools.
• Strong project management and communication skills.
• Proficient in Microsoft Office (Excel, Word, PowerPoint)
• Strong organizational skills; able to manage priorities and workflow
• Able to work independently and as a member of various teams
• Versatile, flexible, and willing to work within constantly changing priorities with enthusiasm.
• Strong safety background and attendance record

Physical Environment

• Capability to lift items weighing up to 40 pounds.
• Capability to stand or walk for extended periods, up to 8 hours.
• This position may require various physical activities, including but not limited to walking, standing, bending, stretching, and using hands and fingers to grasp, push, and lift items.

Leviat Offers You

• An inclusive and diverse culture that values opportunity for growth, development and internal promotion
• Competitive base pay
• Comprehensive, low-cost medical, dental and disability benefits programs and health and well-being initiatives
• Group retirement savings program