Key Responsibilities and Required Skills for Injection Technician

🎯 Role Definition

An Injection Technician (Injection Molding Technician) is a hands-on manufacturing professional responsible for setting up, operating, troubleshooting, and maintaining injection molding equipment to produce high-quality plastic parts to specification. The role emphasizes machine setup, mold installation, process optimization, part inspection, and preventative maintenance while ensuring compliance with safety, quality systems (ISO/TS), and customer requirements such as PPAP and First Article Inspection. Injection Technicians work closely with process engineers, quality, maintenance, and production teams to reduce downtime, control scrap, and continuously improve molding processes and part consistency.

📈 Career Progression

Typical Career Path

Entry Point From:

Machine Operator or Production Operator with experience in plastics or press operation
Apprenticeship or vocational training in Plastics Technology or Industrial Maintenance
Maintenance Technician or Tooling Technician transitioning into molding operations

Advancement To:

Senior Injection Technician / Lead Molding Technician
Process Engineer or Plastics Process Specialist
Tooling & Mold Maintenance Lead or Tool Room Supervisor
Production Supervisor / Manufacturing Manager

Lateral Moves:

Quality Technician or Quality Engineer (focus on PPAP, Cpk, FAI)
Maintenance Technician (mechanical/electrical/PLC specialization)
Automation/Robotics Technician for molding cell integration

Core Responsibilities

Primary Functions

Set up injection molding machines, install and align molds, connect hot runner systems and temperature control units, and verify clamp tonnage and platen alignment to ensure safe, repeatable molding runs.
Program and verify machine parameters (shot size, injection pressure, hold time, screw speed, melt temperature, mold temperature) on the HMI to achieve target part dimensions and cycle efficiency.
Perform mold changeovers including purge cycles, color changes, and tooling adjustments while minimizing downtime and maintaining part quality during transitions.
Conduct first part inspections and validate process capability by measuring parts to engineering drawings, using calipers, micrometers, optical comparators, and coordinate with CMM/quality for initial sample approval (FAI/PPAP).
Troubleshoot molding defects (short shot, flash, sink, warp, burn, flow lines) using root cause analysis, corrective actions, and process adjustments to eliminate recurrence and reduce scrap rates.
Maintain and adjust machine servo and hydraulic settings, safety interlocks, and clamp controls; coordinate with maintenance for gearbox, hydraulic, or servo repairs when required.
Implement and maintain preventative maintenance tasks for presses, robots, moulds, and auxiliary equipment including lubrication, heater band replacement, and mold cleaning to extend tool life.
Monitor and control material handling processes: schedule and verify resin drying (desiccant/hopper dryers), manage lot codes, and ensure proper resin blending and moisture control to prevent part defects.
Operate and program part extraction automation and auxiliary equipment (pick-and-place robots, conveyors, vision systems) to integrate cycle timing and ensure part handling does not damage assemblies.
Collect and record process data into MES, SPC systems, or paper logs: record cycle times, shot weights, reject counts, downtime reasons, and corrective actions for continuous improvement and traceability.
Execute in-process inspection sampling plans and apply statistical process control (SPC) techniques to monitor key dimensions, compute Cpk/Ppk, and escalate trends that indicate process drift.
Perform mold preventative maintenance and minor repairs such as adjusting ejector pins, replacing wear plates, polishing parting lines, and reporting major mold damage for tooling shop repair.
Support production scheduling by sequencing mold runs, staging materials, and preparing job setups to meet on-time delivery and takt time requirements while minimizing changeover waste.
Participate in new mold trials and product introductions: assist process engineers with mold trials, record process windows, complete trial reports, and provide practical feedback on tooling or gating changes.
Ensure strict adherence to safety policies: verify safety guards, follow lockout/tagout (LOTO) procedures during maintenance, and participate in safety audits and machine risk assessments.
Execute root cause investigations for recurring quality or downtime issues, lead containment actions, and implement corrective/preventive measures such as fixture redesign, process standardization, or operator training.
Maintain housekeeping and 5S standards in the molding cell including cleaning sprues, organized tooling shelves, and labeled spare parts to ensure efficient and safe workflows.
Train and mentor junior technicians and operators on machine operation, setup best practices, quality checks, and troubleshooting methods to build team competency and reduce dependency on engineering support.
Support customer and internal audits by providing process documentation, FAI/PPAP packages, traceability records, and evidence of implemented corrective actions for nonconforming parts.
Coordinate with materials engineering, tooling vendors, and internal maintenance to manage die/mold repairs, shipping/receiving of tooling, and replacement of critical components to reduce lead times.
Execute continuous improvement projects (Kaizen) focused on cycle time reduction, scrap reduction, energy consumption improvements, and automation opportunities to improve cost-per-part.
Maintain accurate job documentation and changeover checklists, update standard operating procedures (SOPs), and ensure that production records reflect approved process settings and change history.
Monitor environmental and regulatory compliance for polymer handling, safe disposal of purge materials, and adherence to workplace chemical safety (MSDS/SDS) for resins, colorants, and cleaners.
Assist in downtime recovery for unplanned events by coordinating cross-functional resources, performing temporary fixes, and facilitating rapid mold swaps or process rework when required.

Secondary Functions

Support training programs by developing practical troubleshooting guides, standard work instructions, and cross-training schedules for multi-shift coverage.
Assist quality engineering with corrective action requests (CARs), root cause verification, and long-term corrective implementation related to molding operations.
Participate in continuous improvement sprints and cost reduction initiatives by generating data-backed proposals for tooling changes, process optimization, and automation investments.
Help schedule and manage spare parts inventory for molds, heating/cooling components, and wear items to reduce critical downtime risk.
Provide technical input to procurement for new molds, machinery upgrades, and automation equipment, including specifications and acceptance criteria.
Collaborate with maintenance to prioritize preventive and predictive maintenance activities based on Pareto analysis of downtime causes.
Support shift handovers by providing concise production summaries, open issues, and action items to incoming technicians and supervisors.
Assist in packaging and kitting for complex assemblies to ensure molded parts enter downstream processes without damage or mismatch.
Maintain vendor relationships for mold repair and specialized machining, coordinating quotes, lead times, and technical feedback for tool improvement.
Participate in periodic machine capability studies and calibration scheduling with metrology and maintenance teams to ensure measurement and machine accuracy.

Required Skills & Competencies

Hard Skills (Technical)

Proficient operation and setup of horizontal and vertical injection molding machines, including hydraulic, electric, and hybrid/servo presses.
Mold changeover expertise: safe installation, alignment, hot-runner hookups, and purge/color change procedures to minimize cycle disruptions.
Hands-on troubleshooting of molding defects (short shots, sink marks, flash, burning) with ability to adjust molding parameters to correct root causes.
Knowledge of mold tooling components and basic repair: ejector systems, lifters, slides, parting lines, and hot runner maintenance.
Experience with SPC and process capability analysis (Cpk/Ppk), sample collection, and interpreting control charts to guide corrective actions.
Use of precision measurement tools (calipers, micrometers, go/no-go gauges, height gauges) and familiarity with CMM reports and GD&T basics.
Working knowledge of PPAP, First Article Inspection (FAI), FMEA principles, and ISO 9001 quality system requirements as they apply to plastics production.
Basic PLC/HMI troubleshooting and configuration, plus experience coordinating with automation/robotics technicians for cell integration.
Material handling and processing knowledge: polymer drying, moisture control, regrind management, color and additive handling, and safe chemical usage per SDS.
Familiarity with MES/ERP systems for job travelers, lot traceability, scrap reporting, and production data entry.
Ability to read and interpret engineering drawings, mold documentation, and process control sheets.
Preventative maintenance skills for presses and auxiliary equipment; ability to perform scheduled lubrication, minor part replacement, and condition checks.
Experience with energy-saving and cycle optimization practices to reduce part cost and energy consumption per shot.

Soft Skills

Strong attention to detail and quality focus to maintain tight tolerances and consistent part acceptance rates.
Excellent problem-solving and root-cause analysis skills with a methodical approach to defect elimination and downtime reduction.
Clear verbal and written communication to document process changes, support shift handovers, and coordinate cross-functional activities.
Teamwork and collaboration: ability to work with engineers, maintenance, quality, and production planners to meet delivery targets.
Time management and prioritization under multi-job and multi-shift conditions to meet takt time and customer commitments.
Continuous improvement mindset and willingness to lead Kaizen events or small projects to boost productivity and reduce waste.
Training and coaching aptitude to mentor less experienced operators and ensure skills retention across shifts.
Adaptability and resilience to work in dynamic manufacturing environments with frequent changeovers and problem resolution.
Safety-first orientation: proactive about identifying hazards, following LOTO, PPE requirements, and reporting near-misses.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED, with evidence of technical aptitude and hands-on mechanical experience.

Preferred Education:

Associate degree or technical certificate in Plastics Technology, Manufacturing Technology, Mechanical Engineering Technology, or Industrial Maintenance.
Industry certifications such as Injection Molding Technician certifications, OSHA 10/30, or Six Sigma Yellow Belt are advantageous.

Relevant Fields of Study:

Plastics Engineering / Plastics Technology
Mechanical Engineering Technology
Industrial Maintenance / Mechatronics
Manufacturing Engineering / Production Technology

Experience Requirements

Typical Experience Range:

1 to 7+ years of direct injection molding experience depending on role seniority; most mid-level Injection Technicians have 2–5 years of hands-on molding experience.

Preferred:

3+ years of progressive injection molding experience on automated production cells, including machine setup, mold changeover, and SPC-based quality control.
Prior exposure to PPAP/FAI processes, troubleshooting complex molding defects, and performing preventive maintenance on presses and auxiliary equipment.