Key Responsibilities and Required Skills for Injection Molding Process Technician

🎯 Role Definition

The Injection Molding Process Technician is a hands-on manufacturing professional responsible for setting up, operating, tuning, troubleshooting and maintaining injection molding machines and molds to produce high-quality plastic parts. This role focuses on achieving consistent part quality, optimizing cycle times and yields, executing mold changeovers, performing root-cause problem solving, and partnering with engineering, tooling and quality teams to implement continuous improvements and sustain production targets while meeting safety and regulatory requirements.

📈 Career Progression

Typical Career Path

Entry Point From:

Machine Operator (Injection Molding)
Mold Technician / Toolmaker Apprentice
Maintenance Technician (manufacturing)

Advancement To:

Injection Molding Process Lead / Supervisor
Process Engineer (Plastics)
Tooling/Mold Maintenance Supervisor
Production Manager

Lateral Moves:

Quality Technician / Inspector (plastics)
Industrial Maintenance Technician
Mold Maintenance / Toolmaker

Core Responsibilities

Primary Functions

Set up and perform mold changeovers on hydraulic, hybrid and all-electric injection molding machines, including installation of molds, alignment, hydraulic/electrical hook-ups, hot-runner connections and verification of venting and ejector systems.
Program and adjust machine process parameters (temperatures, hold/pack profiles, injection speed/pressure, screw/back pressure, clamp force and shot size) to achieve first-time-right production and minimize scrap.
Run mold trials and first article validations, document process windows, and hand off validated process instructions and SPC control plans to production teams and engineering.
Diagnose and troubleshoot process-related defects such as short shots, flash, sink, burn marks, weld lines, dimensional variation and cosmetic issues using root cause analysis tools (5 Whys, fishbone, DMAIC).
Perform preventative and corrective maintenance on molds and auxiliary equipment (hot runners, mold temperature controllers, dryers, material loaders, robots and conveyors) to minimize downtime and extend mold life.
Calibrate and use precision measuring instruments (calipers, micrometers, height gauges, gauges) and coordinate with CMM/QC labs to verify part dimensions and tolerances against blueprints and customer specifications.
Implement and maintain Statistical Process Control (SPC) charts, record control limits, trigger investigation for out-of-control trends and lead corrective actions to stabilize processes.
Conduct resin handling and processing procedures, including resin drying, blending, moisture control, material changeovers and contamination prevention per material safety data sheets and molding specs.
Lead continuous improvement initiatives (Kaizen events, 5S, SMED) to reduce cycle time, tooling setup time, scrap and production costs while improving throughput and quality.
Maintain complete and accurate production documentation including mold logs, setup sheets, downtime reports, scrap reports, corrective action records and first article inspection reports.
Work closely with toolmakers and vendors to identify and prioritize mold repairs, recommend design changes to improve partability and ease of maintenance, and coordinate mold shipping/receiving for refurbishment.
Adjust and program automation (pick-and-place robots, part manipulators, sprue/purge systems) and safety interlocks to optimize part handling, reduce labor and maintain consistent takt time.
Enforce safety protocols, lockout/tagout, machine guarding, PPE requirements and workplace ergonomics while reporting safety incidents and participating in safety improvement activities.
Support molding process validations for new product launches, including capability studies (Cp/Cpk), process flow documentation, and update of work instructions and process control plans.
Interpret engineering drawings, GD&T callouts and customer specifications to ensure parts meet functional and aesthetic requirements; escalate ambiguous requirements to engineering.
Troubleshoot machine PLC alarms and basic controls; collaborate with maintenance/automation teams for advanced PLC and servo issues to restore production quickly.
Manage production priorities and schedules, coordinate with production planning and material coordinators to ensure raw material availability and on-time delivery of runs.
Train and mentor operators on correct machine setup, good molding practices, part inspection, prevention of contamination and basic troubleshooting to raise overall shop capability.
Monitor and control process capability metrics and production KPIs (yield, OEE, scrap rate, cycle time) and prepare regular shift handoff reports that summarize performance and outstanding actions.
Conduct mold cleaning, polishing, and basic in-house mold repairs (bushing changes, ejector pin replacement, minor gating changes) under tooling best-practices to prevent recurring defects.
Lead containment and corrective action in response to customer quality issues, including root cause investigation, 8D report support, and implementation of permanent countermeasures.
Coordinate sample shipments, production verification runs and documentation for PPAP/PPG submissions, customer audits and regulatory compliance where applicable.
Maintain inventory and condition tracking of critical spare parts for molds and presses to reduce mean time to repair and protect production readiness.
Validate and maintain process settings in manufacturing execution systems (MES) or ERP (SAP, Oracle) including recipes, tooling IDs and serial numbers used for traceability.
Monitor environmental controls for temperature-sensitive molding operations and advise on climate mitigation steps when process variation is linked to ambient conditions.

Secondary Functions

Support engineering efforts for new product development by providing practical injection molding feedback on design for manufacturability (DFM) and recommended gating/runners/ejector placements.
Assist quality and production teams with ad-hoc data pulls, production analytics and trend analysis to identify opportunities for continuous improvement.
Contribute to the plant’s continuous improvement roadmap by proposing process enhancements and participating in cross-functional improvement teams.
Participate in production planning meetings to translate scheduling needs into realistic molding capacity and tooling availability plans.
Mentor junior technicians and contribute to the formal training curriculum for new hires on injection molding best practices and safety.

Required Skills & Competencies

Hard Skills (Technical)

Injection molding machine setup and operation (hydraulic, pneumatic, electric presses)
Mold changeovers, mold maintenance and basic mold repair techniques
Process parameter optimization: temperature control, injection/hold profiles, screw speed, clamp force
Statistical Process Control (SPC) and capability analysis (Cp/Cpk)
Root cause analysis tools (5 Whys, Fishbone, 8D, DMAIC)
Blueprint reading and GD&T interpretation for plastic parts
Precision measuring instruments: calipers, micrometers, height gauges; familiarity with CMM output
Resin handling, drying, desiccant systems, and material changeover procedures
Hot runner systems and troubleshooting
Basic PLC/machine control troubleshooting and human-machine interface (HMI) operation
Use of MES/ERP systems for recipe and tooling management (SAP, Oracle, or equivalent)
Familiarity with molding simulation outputs (Moldflow) and DFM for plastics
Preventive maintenance scheduling and use of maintenance management systems (CMMS)
Automation integration (robot programming basics, pick-and-place) and safety interlocks
Quality systems knowledge (ISO 9001, IATF 16949 where applicable) and PPAP documentation

Soft Skills

Strong problem-solving and analytical thinking with a data-driven mindset
Clear verbal and written communication for shift handoffs and cross-functional collaboration
Attention to detail and commitment to high-quality workmanship and documentation
Team player with ability to train, mentor and influence operators and peers
Time management and ability to prioritize tasks in a fast-paced production environment
Proactive continuous improvement orientation and willingness to lead change
Flexibility to support multiple shifts and respond to urgent production issues
Safety-first attitude and adherence to established safety and compliance procedures

Education & Experience

Educational Background

Minimum Education:
High school diploma or equivalent (GED) with vocational training or relevant trade certification.

Preferred Education:
Associate degree or technical certificate in Plastics Technology, Process Technology, Tool & Die, Mechanical Engineering Technology or equivalent.

Relevant Fields of Study:

Plastics Technology / Polymer Science
Mechanical Engineering Technology
Tool & Die / Moldmaking
Industrial Maintenance / Mechatronics

Experience Requirements

Typical Experience Range:
2–7 years of hands-on experience in injection molding production, mold setup, and troubleshooting.

Preferred:
3–5+ years of injection molding process technician experience in a high-volume manufacturing environment, demonstrated success in SPC/process capability improvement, experience with hot-runner systems, mold trials and continuous improvement projects. Experience with ISO quality systems, SAP/MES, and automation integration is highly desirable.