Sr. Process Engineer

Ingersoll Rand is an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.

Job Title: Sr. Process Engineer

Location: Lincolnshire, IL

About Us: Imagine a company with technology leadership of over 160 years, yet it operates with the energy of a startup. Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission-critical flow creation and life science technologies – from compressors to precision handling of liquids, gasses, and powers – to increase industrial productivity, efficiency, and sustainability. Supported by over 80+ brands, our products are used in various end-markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more. Across the globe, we’re driving growth with an entrepreneurial spirit and ownership mindset. Learn more at irco.com and join us to own your future.

Job Overview: The Process Engineer is responsible for the development, optimization and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer and compression molding processes. The Process Engineer plays a key role in driving process capability, optimizing cycle times, reducing scrap, troubleshooting production issues and ensuring stable manufacturing performance across all molding work centers.

The Process Engineer collaborates closely with the Tooling, Production, Quality, NPI and Maintenance teams to ensure successful product launches, consistent quality and efficient manufacturing processes.

Responsibilities: Process Development & Optimization:

• Develop, validate and optimize molding processes for:
• LSR injection molding.
• HCR injection, compression and transfer molding.
• Multi-cavity, family molds and multi-shot configurations.
• Apply scientific molding techniques to establish:
• Injection/fill profiles.
• Pack/hold strategies.
• Cure and thermal control profiles.
• Venting and flash prevention parameters.
• Performs process determination and DOE studies to optimize process by improving capability (Cp/Cpk) and reducing variation.
• Establish and maintain standardized process parameter sheets, recipes and work instructions.

Troubleshooting & Technical Support:

• Provide daily technical support to address molding issues such as:
• Flash, short shots, cure variations, knit lines and voids.
• Sticking and ejection problems.
• Inconsistent shrink, durometer and dimensional stability.
• Lead structured root cause analysis (5 why, 8D, fishbone) and implement robust corrective and preventative actions.
• Train operators and technicians in molding best practices and process discipline.

Tooling & Equipment Interaction:

• Partner with Tooling Engineer on:
• Gate/vent design for silicone and rubber molds.
• Cold runner or valve-gate LSR systems.
• Mold thermal management and vent maintenance.
• Mold qualification and production readiness.
• Support maintenance to ensure equipment (presses, injection units, dosing systems, thermolators) operate within validated performance parameters.
• Provide feedback to improve mold robustness, reduce tool wear and minimize flash related issues.

Continuous Improvement:

• Drive improvements in:
• Cycle time optimization.
• Scrap and rework reduction.
• OEE (availability, performance and quality).
• Material usage and yield optimization.
• Participate in LEAN, Kaizen, 5S and efficiency projects.
• Use SPC, data analytics and process monitoring to identify and address instability.

Cross-Functional Collaboration:

• Work with NPI Engineering on:
• Feasability reviews.
• New mold trials and qualification.
• Launch readiness and transfer to production.
• Support Quoting/Estimating with:
• Cycle time projections.
• Material behavior expectations.
• Cavitation/tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks and improvement projects.

General Accountability:

• Cooperation and professional conduct with coworkers, staff, and managers.
• Communicate effectively with Flexan’ s employees and Management. Demonstrates all the Flexan corporate values.
• Quality
• Accountability
• Respect
• Innovation
• Integrity
• Open & honest communications
• Teamwork
• Customer focus

Requirements:

• Bachelor’s degree in an Engineering (Mechanical, Manufacturing, Materials, Plastics, Polymer)/
• 5+ years’ direct experience in silicone and/or rubber molding, with strong understanding of:
• Liquid Silicone Rubber (LSR) injection.
• High Consistency Rubber (HCR) molding.
• Compression and transfer molding.
• Cure cycles, post-cure and material behavior.
• Tool design elements (cavitation, gating, venting, steel types).
• Experience using DOE, SPC and statistical tools for process improvement.
• Strong ability to interpret engineering drawings, GD & T, CAD models, customer and regulatory specifications.
• Demonstrated success in troubleshooting complex molding issues.

Preferences:

• Experience with SolidWorks or other 3D modelling software.
• Experience with mold flow analysis (or ability to interpret results).
• Background in medical, automotive, aerospace or industrial silicone components.
• Experience supporting APQP, PPAP and customer audits.
• Experience with automation, vision inspection and deflashing/trimming technologies.
• Background with adhesion/bonding techniques, multi-shot molding and overmolding.
• RJG/Paulson certification or silicone-specific molding training.
• Familiarity with ISO13485 and clean room procedures would be beneficial.

Travel & Work Arrangements/Requirements: Onsite.

The pay range for this role is $100-$125k. The pay range considers a wide range of factors that include a candidate’s skills; experience and training; licensure and certifications; and geographic location.

What We Offer: At Ingersoll Rand, we embrace a culture of personal ownership — taking responsibility for our company, our communities, and our environment, as well as our individual health and well-being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together, we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401(k) plan, paid time off, and even an employee stock grant, among other offerings. These benefits are our commitment to you, so you can be your best at work and beyond.

Ingersoll Rand Inc. (NYSE:IR), driven by an entrepreneurial spirit and ownership mindset, is dedicated to helping make life better for our employees, customers and communities. Customers lean on us for our technology-driven excellence in mission-critical flow creation and industrial solutions across 40+ respected brands where our products and services excel in the most complex and harsh conditions. Our employees develop customers for life through their daily commitment to expertise, productivity and efficiency. For more information, visit www.IRCO.com.

What We Offer At Ingersoll Rand, we embrace a culture of personal ownership — taking responsibility for our company, our communities, and our environment, as well as our individual health and well-being. Our comprehensive benefits package is designed to empower you with the tools and support necessary to take charge of your health, ensuring that together, we can continue to make life better. Our range of benefits includes health care options like medical and prescription plans, dental and vision coverage, as well as wellness programs. Additionally, we provide life insurance, a robust 401(k) plan, paid time off, and even an employee stock grant, among other offerings. These benefits are our commitment to you, so you can be your best at work and beyond.

Ingersoll Rand is committed to achieving workforce diversity reflective of our communities. We are an equal opportunity employer. All qualified applicants will receive consideration for employment without regard to age, ancestry, color, family or medical care leave, gender identity or expression, genetic information, marital status, medical condition, national origin, physical or mental disability, political affiliation, protected veteran status, race, religion, sex (including pregnancy), sexual orientation, or any other characteristic protected by applicable laws, regulations and ordinances.