Senior Process Technician - Injection Molding

Company Description

Gerresheimer is the global partner for pharmaceutics, biotech, healthcare, and cosmetics with a very broad product range for pharmaceutical and cosmetic packaging solutions and drug delivery systems. The company is an innovative solution provider from concept to delivery of the end product. Gerresheimer achieves its ambitious goals through a high level of innovative strength, industrial competence and concentration on quality and customer focus. In developing innovative and sustainable solutions, Gerresheimer relies on a comprehensive international network with numerous innovation and production centers in Europe, America and Asia. Gerresheimer produces close to its customers worldwide with around 11,000 employees and generated annual revenues in 2022 of EUR 1.8bn. With its products and solutions, Gerresheimer plays an essential role in people's health and well-being.

Gerresheimer Peachtree City L.P. was established in 1993 in Peachtree City, GA, as part of the Plastics & Devices Division manufacturing and assembling a variety of precision molded plastic parts for various applications in the medical industry. 

https://www.gerresheimer.com/

Job Description

The Senior Process Technician is responsible for setting up, optimizing, and maintaining injection molding equipment to produce high-quality plastic components. This role serves as a technical leader on the production floor, mentoring junior technicians, troubleshooting process issues, and driving continuous improvement initiatives. The ideal candidate brings deep knowledge of injection molding processes, strong analytical skills, and a commitment to safety and quality.

Process Setup & Optimization

• Set up and start up injection molding machines (50–2,000+ ton) according to established process parameters and traveler documentation
• Develop, refine, and document robust molding processes, including fill studies, gate seal, and cushion analysis
• Optimize cycle times, shot weights, temperatures, pressures, and cooling profiles to meet quality and efficiency targets
• Perform mold validations (IQ/OQ/PQ) and first article inspections in coordination with quality and engineering teams
• Conduct Scientific Injection Molding (RJG or equivalent) studies to ensure process repeatability and capability

Troubleshooting & Quality

• Diagnose and resolve process-related defects including short shots, flash, sink marks, warpage, weld lines, splay, and dimensional non-conformance
• Collaborate with toolroom and engineering on mold repairs, preventive maintenance, and process improvements
• Monitor and interpret SPC data; respond to out-of-control conditions and initiate corrective actions
• Support root cause analysis (RCA) and lead 8D or A3 problem-solving efforts for recurring process issues

Leadership & Training

• Mentor and coach Process Technicians I & II on setup procedures, process fundamentals, and troubleshooting techniques
• Conduct on-the-job training and contribute to the development of work instructions and training materials
• Serve as the go-to technical resource during shift operations in the absence of Process Engineering staff
• Lead or participate in Kaizen events and lean manufacturing projects on the production floor

Documentation & Compliance

• Maintain accurate process sheets, change logs, and setup documentation in the MES/ERP system
• Ensure compliance with ISO 9001, IATF 16949, ISO 13485, or applicable quality management systems
• Adhere to all safety protocols including lockout/tagout (LOTO), PPE requirements, and machine guarding standards
• Participate in internal audits and support customer/third-party audits as needed
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Qualifications

Required

• High school diploma or GED; technical degree or vocational certification in plastics technology preferred
• Minimum 5 years of hands-on injection molding experience, including at least 2 years in a senior or lead technician role
• Proficiency with a wide range of injection molding presses from multiple OEMs (e.g., Engel, Husky, Arburg, Milacron, Van Dorn)
• Working knowledge of mold components, hot runner systems, hydraulic and electric press operations
• Strong understanding of plastic material properties (ABS, PC, PA, PP, TPE, LCP, etc.) and their processing characteristics
• Ability to read and interpret engineering drawings, GD&T, and material data sheets
• Experience with process documentation and quality systems (ISO, IATF, FDA/GMP environments)

Preferred

• RJG Master Molder II or equivalent Scientific Molding certification
• Experience with hot runner control