Job Description

Company Overview Our client is an Established High-Precision Engineering & Custom Injection Moulding Corporation , specializing in complex technical plastics, multi-cavity precision components, and electro-mechanical sub-assemblies for global electronics, automotive, and industrial tier-1 customers. Supported by advanced machine architectures, automated resin handling, and in-house toolroom facilities, the organization operates advanced production plants across Selangor and Melaka . To strengthen technical self-reliance on the shopfloor at the Seri Kembangan HQ plant—where executive management frequently travels between regional sites—the company is seeking an experienced, technically sound Senior Process Engineer . Position Overview The Senior Process Engineer is the primary technical authority on the shopfloor, bridging deep scientific moulding execution with daily team leadership. This role is responsible for driving production smoothness, optimizing machine cycle times, eliminating part defects, and qualifying new resins and moulds . A critical differentiator for this seat is genuine hands-on technical problem-solving combined with floor-level leadership : the incumbent cannot be purely theoretical or administrative. You must be able to personally diagnose resin degradation, hot runner issues, or barrel temperature curves at the machine, lead 8D root-cause investigations on customer complaints, coordinate tool repairs with QA/Tooling, and mentor a 24-member technical crew to maintain shift discipline and process stability . Key Responsibilities 1. 70% Hands-On Technical Troubleshooting & Scientific Moulding Serve as the go-to technical authority on the shopfloor to troubleshoot stubborn injection moulding defects (sink marks, flash, jetting, short shot, warpage, silver streaks/moisture, burn marks, dimensional drift) . Apply scientific moulding principles to establish robust processing windows, optimizing injection speed, pack/hold pressures, cooling times, switch-over points, and clamp tonnage . Own plastic resin parameters and material processing standards: audit drying hopper temperatures, dehumidifying cycles, barrel temperature profiles, melt temperatures, and shear sensitivity for engineering and commodity resins . Conduct root-cause investigations on tooling and hot-runner malfunctions (valve gates, hot tips, manifold leaks, thermocouple failures, heating zones), liaising directly with Tooling to issue Mould Repair / Modification Requisitions . Lead process trials for New Product Introduction (NPI), new mould qualifications, resin conversions, and cycle-time debottlenecking . 2. 30% Shopfloor Leadership & Team Capability Building Direct, lead, and organize the daily work routines of a 24-person technical team: 1 Junior Process Engineer, 1 Technical Supervisor, 2 Assistant Supervisors, 10 Technicians, and 10 Material Handlers. Build internal technical depth by conducting structured classroom and on-the-machine training for technicians and supervisors covering resin properties, mould mechanisms, and systematic troubleshooting . Maintain shift discipline, safety standards (ISO 45001), 5S shopfloor hygiene, and ensure production handover routines run smoothly without requiring executive escalation . 3. Quality, Customer Feedback & Cross-Departmental Liaison Directly investigate customer returns, non-conformance reports, and quality complaints; prepare technical 8D reports, corrective action plans (CAPA), and update Management Review Meeting (MRM) data . Partner closely with Quality Assurance (QA) to establish Limit Samples, boundary boards, and inspection criteria to minimize the Cost of Poor Quality (COPQ) . Collaborate with the Maintenance department to issue work orders, schedule preventative maintenance on presses/auxiliaries, and maintain hydraulic/electric machine stability . Requirements Education: Bachelor’s Degree or Diploma in Mechanical Engineering, Manufacturing Engineering, Polymer Engineering, Materials Science, or equivalent practical background . Work Experience: Minimum 5+ years of hands-on process engineering experience specifically within high-precision plastic injection moulding manufacturing . Technical Mastery: Deep practical knowledge of engineering plastics (e. g., PC, ABS, POM, PBT, PA6/PA66, PMMA, PPS, modified blends), including exact drying curves, hygroscopic behaviors, melt processing windows, and degradation thresholds. Thorough understanding of mould construction, sliding cores, lifters, cooling channels, and hot runner architectures (open gate, valve gate, manifold heaters, temperature controllers). Hands-on proficiency setting up and optimizing injection moulding machinery (e. g., Sumitomo, Fanuc, Nissei, Engel, Haitian). Working knowledge of Scientific Moulding, DOE, Lean Six Sigma, and ISO 9001 / ISO 45001 systems . Leadership & Traits: Demonstrated track record of leading, mentoring, and organizing shift technicians and supervisors. Resilient, independent, and capable of holding down plant technical operations autonomously while management travels between sites. Language & Communication: Strong communication skills in English and Bahasa Malaysia; ability to articulate technical root causes clearly in customer-facing and internal reports.