Key Responsibilities and Required Skills for Molding Process Quality Technician

🎯 Role Definition

The Molding Process Quality Technician is responsible for ensuring molded parts meet customer and internal quality standards by monitoring injection molding or extrusion processes, performing dimensional and visual inspections, launching corrective actions, and supporting continuous improvement (CI) initiatives. This hands-on quality role blends inspection, data analysis (SPC/CpCpk), problem solving (8D/root cause), and collaboration with production, engineering, and suppliers to reduce defects, improve process capability, and maintain compliance with quality management systems (ISO/TS, IATF).

📈 Career Progression

Typical Career Path

Entry Point From:

Quality Inspector (plastics/injection molding)
Machine Operator or Mold Setter (injection molding)
Manufacturing Technician or Tooling Technician

Advancement To:

Process Engineer (Molding)
Quality Engineer (Supplier or Manufacturing Quality)
Manufacturing Supervisor or Production Manager
Continuous Improvement / Lean Specialist

Lateral Moves:

Tooling / Mold Maintenance Technician
Supplier Quality Engineer
Metrology / CMM Technician

Core Responsibilities

Primary Functions

Inspect and verify molded parts and assemblies using precision instruments (calipers, micrometers, height gauges, optical comparators, and coordinate measuring machines — CMM) to confirm compliance to print, GD&T and customer requirements; document inspection results in quality records and ERP systems.
Perform First Article Inspections (FAI) and generate comprehensive FAI reports for new products and tooling changes, ensuring correct dimensions, material, gate location, and part function prior to production release.
Establish, maintain and execute Statistical Process Control (SPC) plans — collect samples, create control charts, monitor trends and alarms, and recommend corrective actions when process capability (Cp/Cpk) falls below target.
Lead root cause investigations for nonconforming parts using structured methodologies (8D, 5Whys, fishbone diagrams) and drive cross-functional corrective and preventive actions (CAPA) through closure and verification.
Develop and maintain Control Plans, inspection instructions, and standard operating procedures (SOPs) for molding operations to ensure repeatable, capable processes and consistent quality outputs.
Execute Gage R&R studies, manage gage calibration schedules, and ensure measurement systems are qualified, documented, and fit for purpose.
Validate and support mold tryouts and start-up activities: document process settings, optimize cycle parameters (temperatures, injection speed, hold pressure, cooling time), and perform trial runs to achieve target yield and quality.
Work collaboratively with Process Engineering and Maintenance to troubleshoot molding machine issues (hydraulics, temperature control, screw/barrel wear), recommend machine parameter adjustments, and support preventive maintenance to reduce downtime and scrap.
Generate, review and submit PPAP packages and customer-required documentation; lead or support customer-specific quality requirements and audits.
Perform dimensional layout and feature-specific inspection using CMM programming or offline metrology software; interpret engineering drawings, tolerances, and GD&T to ensure part conformity.
Monitor and report scrap, rework and yield metrics daily; identify trends, quantify loss drivers, and implement containment and long-term corrective actions to improve OEE and reduce cost.
Support New Product Introduction (NPI) by participating in design reviews, mold qualification, process development, and first-run validation to ensure manufacturability and quality readiness.
Conduct material and process verification, including identification and traceability of resins, colorants, and additives; work with suppliers to resolve material-related nonconformances.
Execute dimensional and functional electrical/fit checks for assemblies, and document functional test results as required by customer specifications.
Train production operators and mold setters on inspection criteria, defect recognition, correct sampling methods, and in-process controls to improve first-pass yield.
Maintain accurate quality documentation, inspection records, nonconformance reports (NCRs), corrective action records, and calibration logs in compliance with the QMS.
Implement and support continuous improvement projects (Lean, 5S, Kaizen) that drive defect reduction, cycle time improvements, and cost savings in molding operations.
Coordinate and host internal and external supplier/capability audits; respond to audit findings, develop corrective actions, and verify corrective action effectiveness.
Work directly with suppliers and tool vendors to troubleshoot mold tooling issues (wear, venting, cooling) and coordinate mold repairs, rework, or redesign as needed.
Perform visual inspections and defect classification (flow lines, sink, flash, short shot, burn, weld lines, voids) and use defect data to implement poka-yoke, tooling, or process fixes.
Execute measurement and inspection tasks for thermal and mechanical part characteristics when required (e.g., tensile, hardness, wall thickness).
Use statistical software (e.g., Minitab) and Excel to analyze process data, calculate capability, perform DOE to optimize process windows, and prepare executive quality summaries.
Manage nonconforming material containment and disposition, including quarantine, rework instructions, scrap authorization, and customer notifications when applicable.
Ensure compliance with safety, environmental and regulatory requirements relevant to plastics processing and lab/inspection areas.

Secondary Functions

Support customer quality inquiries and technical support requests, providing data packages, root cause reports, and corrective action plans.
Assist in supplier quality development — perform incoming part inspection, supplier audits, and capability studies to ensure purchased components meet molding assembly requirements.
Maintain and calibrate inspection equipment and fixtures; coordinate external calibrations and ensure up-to-date traceability and labeling of gauges.
Prepare and present quality metrics, trend analyses, and project status reports to manufacturing and leadership teams.
Participate in cross-functional product reviews, design for manufacturability (DFM) meetings, and change control boards to minimize quality risk during revisions.
Facilitate knowledge transfer and train new hires on quality processes, documentation standards, and inspection best practices.

Required Skills & Competencies

Hard Skills (Technical)

Injection molding process knowledge (shot size, back pressure, melt temperature, injection speed, packing/hold, cycle cooling) and ability to translate process settings into quality improvements.
Strong dimensional inspection skills: calipers, micrometers, height gauges, optical comparators, and hands-on CMM operation or CMM program reading.
Geometric Dimensioning & Tolerancing (GD&T) interpretation and application to inspection reporting and part acceptance.
Statistical Process Control (SPC) implementation and monitoring; experience creating control charts, calculating Cp/Cpk, and responding to out-of-control signals.
Experience with Minitab, JMP, or equivalent statistical software for DOE, capability studies, and hypothesis testing.
Proficiency with PPAP/FAI documentation, APQP processes, and familiarity with IATF/ISO 9001 quality management system requirements.
Root cause analysis and corrective action methodologies (8D, 5 Whys, fishbone analysis).
Gage R&R studies, measurement system analysis, and gage calibration program management.
Knowledge of FMEA (process and design) and ability to contribute to risk assessments and mitigation plans.
Ability to read and interpret engineering drawings, BOMs, and specifications.
Practical experience with troubleshooting molding machines and supporting tooling maintenance/repair.
Experience with ERP/MRP systems (e.g., SAP) for quality records, nonconformance tracking, and document control.
Basic understanding of PLCs and machine controls as they relate to monitoring process parameters (helpful but not always required).
Familiarity with visual inspection standards, defect classification, and use of magnification or microscopy for small feature inspection.

Soft Skills

Strong analytical thinking and attention to detail with the ability to synthesize data into meaningful corrective actions.
Clear verbal and written communication skills for cross-functional collaboration and customer interactions.
Problem-solving orientation, persistence, and the ability to lead root-cause teams to closure.
Team-player mindset and the ability to influence production, maintenance and engineering stakeholders.
Time management and prioritization skills in fast-paced production environments.
Training and coaching aptitude to upskill operators and technicians on quality best practices.
Adaptability to shifting priorities during mold trials, product launches, and production ramp-ups.
Customer-focused attitude with strong ethical standards and commitment to compliance.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with vocational/technical training in manufacturing or metrology.

Preferred Education:

Associate degree or technical certification in Plastics Technology, Manufacturing Technology, Mechanical Engineering Technology, or Quality Systems.
Certifications such as CQI, ASQ Certified Quality Technician (CQT), or ISO internal auditor are advantageous.

Relevant Fields of Study:

Plastics Technology / Plastics Engineering
Manufacturing Technology / Industrial Maintenance
Mechanical Engineering Technology
Metrology or Quality Engineering

Experience Requirements

Typical Experience Range:

2–5 years of hands-on experience in injection molding or plastics manufacturing quality roles.

Preferred:

3–7+ years of experience specifically in injection molding, extrusion, or thermoplastics process quality, with demonstrated proficiency in SPC, PPAP, FAI, and root-cause analysis.
Prior exposure to automotive, medical device, consumer goods, or aerospace quality standards is highly desirable.