Key Responsibilities
Process Management & Optimisation
* Oversee day-to-day injection moulding operations, ensuring machines, tooling, and ancillary equipment run to optimum performance.
* Establish, maintain, and improve robust process settings, ensuring repeatability and consistency.
* Develop and update process documentation including SOPs, work instructions, and setup sheets.
* Lead root-cause analysis and corrective actions for scrap, downtime, and quality deviations.
* Monitor and improve key KPIs such as OEE, cycle time, material usage, scrap rate, and energy consumption.
Technical Leadership
* Act as the site’s subject-matter expert for injection moulding technology, troubleshooting complex moulding issues.
* Support new product introduction (NPI), including trial planning, tool validation, process development, and capability studies.
* Collaborate with tooling engineers, quality teams, and suppliers to resolve tooling or material issues.
* Ensure moulds are set correctly, safely, and efficiently, implementing best practices across all shifts.
Team Leadership & Training
* Lead, mentor, and develop Process Technicians, Setters, and Operators.
* Deliver training programmes to build technical competence across the team.
* Drive a culture of high performance, accountability, safety awareness, and continuous improvement.
Quality & Compliance
* Maintain compliance with relevant UK and industry regulations (H&S, ISO 9001, ISO 14001, IATF 16949 where applicable).
* Ensure quality standards are achieved through robust process control and in-line inspection methods.
* Work closely with the Quality department on defect analysis, PPAP, FMEA, and control plans.
Continuous Improvement
* Lead CI activities using lean tools (5S, Kaizen, SMED, Poka‑Yoke, SPC).
* Identify opportunities to reduce cycle time, improve yield, and enhance reliability of tools and equipment.
* Support capital investment planning for moulding machines, robotics, automation, and tooling improvements.
Skills & Experience Required
Essential
Significant experience in injection moulding within a manufacturing environment.
Strong understanding of polymer processing, tooling design, materials behaviour, and machine hydraulics/controls.
Demonstrated ability to troubleshoot complex process and tooling issues.
Experience in process optimisation, capability studies, and root‑cause problem solving.
Leadership experience managing teams in a production environment.
Strong understanding of lean manufacturing and continuous improvement methods.
Excellent communication, coaching, and organisational skills.
Desirable
Formal qualifications in Polymer Processing, Mechanical Engineering, Manufacturing Engineering, or equivalent.
Experience with automation, robotics, and Industry 4.0 systems.
Knowledge of automotive, medical, or high-volume consumer goods manufacturing.
Experience working with ERP/MES systems.
Personal Attributes
Proactive and solutions-driven.
Strong attention to detail.
Hands-on and confident in a fast-paced production setting.
Committed to safety, quality, and continuous improvement.
Ability to influence, lead, and develop technical teams
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