Manufacturing Engineer – Plastics Focus

Description

 

PURPOSE:

The Manufacturing Engineer (Plastics) will lead the development, optimization, and implementation of advanced manufacturing technologies and processes for composite, extrusion, and injection molding applications in aerospace and defense. The engineer will drive new product introductions, support ongoing production, and champion continuous improvement initiatives to enhance safety, quality, productivity, and cost-effectiveness. The position blends hands-on engineering with strategic process development, tooling design, and cross-functional collaboration.

 

DUTIES / RESPONSIBILITIES (List what the incumbent is required to do):

New Product Development & Transfer to Production

Lead transition of ballistic, impact-resistant, and plastic-based systems from design to production

Collaborate with cross-functional teams to ensure tool development, process readiness, and manufacturability

Conduct design reviews, calibrations, and pre-production builds

Process Optimization & Troubleshooting

Analyze and improve legacy processes using Lean and Six Sigma tools

Lead root cause investigations and implement corrective actions

Monitor production lines and identify yield improvements using SPC

Transform batch systems into continuous flow lines and balance operations to Takt Time

Develop critical parameters for plastic extrusion and injection molding processes

Evaluate resin formulations and extrusion parameters to meet product specs

 

Technical Leadership & Innovation

Research and recommend new manufacturing technologies, including automation and AI

Lead tooling design, procurement, and fabrication for cost-effective production

Manage equipment lifecycle and support tooling rework and qualification

Conduct experimental trials to eliminate scrap and replace obsolete materials

Support audits and ensure compliance with industry standards

 

Cross-functional Support

Provide technical support to manufacturing, purchasing, production control, and quality assurance

Resolve supplier issues and process problems impacting performance and quality

Interface across all organizational levels to communicate findings and drive action

Train employees on new processes and best practices

Develop Standard Work Instructions, PFMEAs, control plans, and process documentation

Be able to communicate to all levels of the organization through written or verbal format when it comes to advice on incident investigation, corrective action, collecting, recording, and transcribing data, as well as showing results in various types of reports

Research and purchase new manufacturing technology

Schedule flexibility to support critical deadlines may be required

Requirements

 

EDUCATION AND/OR PROFESSIONAL LICENSE(s):

Bachelor of Science degree in Plastics Engineering, Materials Engineering, Mechanical or Industrial Engineering, Manufacturing Engineering or equivalent technical degree is required. Advanced Degree Preferred

 

EXPERIENCE:

2-5 years of experience in manufacturing engineering, preferably in aerospace/defense or high-performance plastics/composites

Strong background in extrusion, injection molding, composite materials, and secondary operations

Experience developing manufacturing documentation (MCPs, SWIs, BOMs, Labor Routings)

Familiarity with optics resin systems, dye packages, or colorants is a plus

 

KNOWLEDGE, SKILLS, AND ABILITIES:

Deep understanding of composite and plastic manufacturing processes, tooling, and design for manufacturability

Proficient in Lean, Six Sigma, DMAIC, Kaizen; certification preferred

Skilled in PFMEA, SPC, GD&T, root cause analysis, and process capability studies

SolidWorks (3D modeling), Microsoft Office Suite, Visio, Project, and Minitab proficiency

Strong communication and organizational skills; able to manage multiple priorities

Familiarity with AS9100 standards and NPI stage gates

Ability to lead design reviews, experimental trials, and process qualifications

Self-starter with a passion for driving change and solving complex manufacturing challenges

 

POSITION SUPERVISES:

Position will be primarily one of an individual contributor. May be required to supervise and coordinate activities with technicians or lab personnel and coordinate with engineers but will not be directly responsible for reporting/evaluating others. Candidate needs to take direction and work independently with minimal supervision.

 

CONTACT WITH OTHERS:

This position requires contact and interaction with a multitude of technical disciplines within GENTEX Corporation, not only within the Carbondale facility, but with “sister” plants throughout the United States.

This position will also require interaction with GENTEX suppliers and occasionally with the customer.

 

PHYSICAL/MENTAL/COMMUNICATION REQUIREMENTS:

Employee is occasionally required to stand; walk; sit; use hands to finger, handle, or feel objects, tools, or controls; reach with hands and arms; climb stairs; balance; stoop, kneel, crouch, or crawl; talk or hear; and taste or smell. The employee may lift and/or move up to 50 lbs. Specific vision abilities required by the job may include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus. The individual must have a high level of comprehension, and a high level of general, verbal, written, and numerical intelligence.

 

WORK ENVIRONMENT:

Works majority of the day in a climate-controlled environment, with the exception of, or otherwise specified, performing work in the warehouse or manufacturing areas which are subject to changes in temperature and/or noise.

 

TRAVEL:

Limited travel required

 

LOCATION:

Gentex’s Carbondale facility is located in Northeastern Pennsylvania in Lackawanna County. Carbondale, PA is about twenty miles north of Scranton, PA, 50 miles south of Binghamton, NY, and about 125 miles from New York City and Philadelphia. The area hosts numerous nearby state parks, nature preserves and local colleges and universities, including The University of Scranton and Marywood University. Northeast Pennsylvania is a beautiful area and offers an excellent cost of living. It is a great place to work, recreate, meet people, raise a family and live!

 

Gentex Corporation is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard for any applicable state or federal protected class. Gentex is an E-Verify Participant. Pre-employment drug/alcohol/background screening is required.