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Senior Plastics Process Engineer

GE Appliances, a Haier company

Louisville, KY

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JOB DETAILS
SKILLS
Artificial Intelligence (AI), Automation, Automation Systems, Continuous Improvement, Corrective Action, Cost Analysis, Cost Control, Cross-Functional, Delivery Management, Diversity, Federal Government, Identify Issues, Injection Molding, Leadership, Lean Manufacturing, Machine Tool, Maintenance Services, Manufacturing, Manufacturing Operations, Manufacturing Systems, Molding Processes, Operational Improvement, Performance Management, Performance Tuning/Optimization, Philosophy, Problem Solving Skills, Process Development, Process Engineering, Process Improvement, Process Validation, Product/Service Launch, Production Part Approval Process (PPAP), Productivity Management, Reliability Engineering, Robotics, Root Cause Analysis, Safety/Work Safety, Startup, System Start-Up, Technical Leadership, Time Management, United States Department of Energy (DOE)
LOCATION
Louisville, KY
POSTED
16 days ago
At GE Appliances, a Haier company, we come together to make “good things, for life.” As the fastest-growing appliance company in the U.S., we’re powered by creators, thinkers and makers who believe that anything is possible and that there’s always a better way. We believe in the power of our people and in giving them the freedom to explore, discover and build good things, together.


The GE Appliances philosophy, backed by three simple commitments defines the way we work, invent, create, do business, and serve our communities: _we come together_ , _we always look for a better way_ , and _we create possibilities_ .


Interested in joining us on our journey?


We are seeking a highly skilled Senior Plastics Process Engineer focusing primarily on Factory Integration & Launch to lead the development, validation, and integration of injection molding processes, tooling, and automation systems within manufacturing operations. This role serves as a technical leader responsible for new product introduction (NPI), transfer of work (TOW), equipment startup, and process optimization ensuring excellence in Safety, Quality, Cost, and Delivery (SQCD). The role also has a strong focus on Maintenance & Repair (M&R) cost reduction and leveraging digital and AI-driven solutions to improve operational performance.


Position

Senior Plastics Process Engineer


Location

USA, Louisville, KY


How You'll Create Possibilities


Injection Molding Process Development & Validation


+ Develop, optimize, and validate injection molding processes for new and existing products

+ Establish scientifically developed molding processes using RJG principles, SPC, and DOE methodologies

+ Define process windows, parameter controls, and ensure repeatability

+ Perform machine qualification, capability studies, and process validation

+ Lead mold trials from initial sampling through PPAP approval


Tool Trials, Launch & Factory Integration


+ Lead tool trials and production readiness for NPI and TOW

+ Drive integration and startup of molding tools, presses, and automation

+ Support robotics programming and EOAT optimization

+ Ensure stable production ramp-up


Troubleshooting, Cost Reduction & Continuous Improvement


+ Troubleshoot molding defects, automation issues, and equipment performance losses

+ Lead root cause analysis and corrective actions for safety, quality, and cost issues

+ Drive M&R cost reduction through equipment reliability improvements and failure elimination

+ Identify and eliminate chronic downtime drivers and maintenance waste

+ Improve OEE, scrap reduction, cycle time, and labor efficiency

+ Apply Lean manufacturing and structured problem-solving methodologies


Digital, Data & AI-Enabled Manufacturing


+ Leverage AI and advanced analytics to identify cost reduction opportunities and predict equipment failures

+ Utilize RJG eDART, CoPilot, and SPC systems to monitor and optimize process performance

+ Apply data-driven insights to reduce scrap, improve yield, and enhance process stability

+ Partner with digital and IT teams to deploy AI tools for predictive maintenance and process optimization

+ Drive adoption of digital technologies to improve decision-making and operational visibility


Project Leadership


+ Lead projects from concept through production launch

+ Coordinate cross-functional teams

+ Manage timelines, deliverables, and launch readiness


What You'll Bring to Our Team


+ Bachelor’s degree in Engineering or equivalent experience

+ 5+ years injection molding experience

+ Strong RJG knowledge (eDART, CoPilot)

+ Experience with robotics, EOAT, and mold trials

+ Strong troubleshooting and problem-solving skills


Preferred Qualifications


+ RJG Master Molder certification

+ Robot programming experience

+ Lean manufacturing experience

+ PPAP and DOE knowledge


Our Culture


Our work is centered on our People and Culture as reflected in our Zero Distance philosophy and we recognize the importance of reaffirming our commitment to inclusion and diversity (I&D). This underscores our commitment to fostering an environment where every individual feels valued, connected, and empowered to contribute, while positioning our organization to adapt seamlessly to the evolving needs of our workforce and communities.


This reflects our dedication to creating solutions that: Empower colleagues by fostering an environment where all voices are heard, valued, and encouraged to contribute. Strengthen communities where we live and work. Reinforce a culture of belonging, purpose, and engagement. Reflect the diversity of the communities we serve through our workforce, products, and practices.


By further embedding Zero Distance into our People and Culture framework, we will continue to build a deeply connected organization. We are cultivating a culture of engagement, belonging, and connection, because while attracting new talent remains a priority, retention is a cornerstone of our strategy.


GE Appliances is a trust-based organization. It is important we offer our employees the flexibility they need to do their best work while balancing the needs of the business and individuals. When you join GE Appliances, you will have the opportunity to work with your leader to create a flexible work arrangement that balances the needs of the individual, team, and organization.


GE Appliances is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.


GE Appliances participates in E-Verify and will provide the federal government with your Form I-9 information to confirm that you are authorized to work in the U.S


_If you are an individual with a disability and need assistance or an accommodation to use our website or to apply, please send an e-mail_ _to ask.recruiting@geappliances.com_

About the Company

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GE Appliances, a Haier company