Senior Plastic Process Engineer

Job Summary

Vaco by Highspring is hiring a Senior Plastic Process Engineer in Walled Lake, Oakland County, US. This hybrid role leads high‑impact thermoforming projects from concept to full‑scale production with a competitive salary of $131,194.75.

Key Responsibilities

• Own the technical development and optimization of plastic thermoforming processes.
• Lead cross‑functional teams to design, qualify, and scale manufacturing equipment.
• Analyze process capability, identify improvement opportunities, and implement corrective actions.
• Develop and maintain detailed process documentation, work instructions, and SOPs.
• Collaborate with product design, quality, and supply chain to ensure manufacturability and cost targets.
• Travel up to 60% to customer sites and manufacturing facilities to support pilot runs and troubleshoot issues.
• Provide training and mentorship to junior engineers and production staff.

Qualifications

• Bachelor’s degree in Mechanical, Materials, or Chemical Engineering (Master’s preferred).
• Minimum 6 years of experience in plastics manufacturing, specifically thermoforming.
• Proven track record of delivering projects from prototype to high‑volume production.
• Strong analytical skills with proficiency in DFMEA, SPC, and statistical process control.
• Excellent communication and stakeholder management abilities.
• Willingness to travel extensively (up to 60%).

Compensation & Benefits

Base salary: $131,194.75 annually. Hybrid work environment with flexible scheduling, comprehensive health benefits, 401(k) match, and professional development opportunities.

Frequently Asked Questions

What type of projects will the Senior Plastic Process Engineer manage?

You will lead thermoforming initiatives from concept through full‑scale production, overseeing equipment design, process optimization, and high‑volume manufacturing.

Is travel required for this position?

Yes, the role involves up to 60% travel to customer sites and manufacturing facilities to support pilot runs and troubleshoot processes.

What are the education and experience requirements?

A Bachelor’s degree in Engineering (Mechanical, Materials, or Chemical) is required, with at least 6 years of plastics manufacturing experience, preferably in thermoforming.