© 2017 by KNAPP MFG., INC.



Position:   Molding Team Leader                                           Department:  Molding

Reports to:     Sr. Vice President                                           FLSA Status: Exempt

Summary of Position

Under the direction of the Sr. Vice President, the Molding Team Leader will be responsible for escalating the performance through SQDCI change efforts in the Molding department by leading organizational development processes, promoting employee engagement and driving quality and productivity improvements.  


Primary Duties and Responsibilities

  • Understand and model the Knapp Required Values.

  • Engineering Expert in Injection Molding in plastic part design, tooling, process development and troubleshooting.

  • Responsible for molded part process engineering, project management and reporting; including project timelines, costs and quality.

  • Responsible for establishing/evolving systems for implementation and integration of new molded products and processes into production ensuring robust process controls are in place. (“Scientific Molding” and in-cavity pressure control philosophies) for new and existing manufactured products and components.  This includes establishment of best practices for tooling and process standard Document, validate and determine standards for them.

  • Responsible for establishing standards for verification, validation, and establishing processes for new molding equipment and molds with control guidance for manufacturing, insuring that processes and products released to manufacturing meet established product specification.  Interfaces with quality and manufacturing to ensure process monitoring and audits result in product conforming to specifications.

  • Responsible for 1st level troubleshooting & repair of injection molding machine and ancillary processing equipment.   (Varying vintages of electro mechanical and computer controlled machinery).

  • Responsible for preparing tooling specifications with assistance from the Innovation & Technology department.

  • Function as the technical expert for the molding department.

  • Support maintain and upgrade production processes, including injection molding, insert molding and assembly.

  • Prepares or reviews documentation with a high degree of accuracy, completeness, and effectiveness using engineering tools and templates where available (i.e. validation documents, specifications, manufacturing procedures, ECOs and technical reports or analysis summaries). 

  • Applies and leads Lean Six Sigma approaches to solve issues and reduce variation in manufacturing and business processes.

  • Consult with Quality, Innovation & Technology and manufacturing personnel regarding machine design, process/product design tooling/fixturing and production problems.

  • Interact with outside vendors to investigate commercial machine and equipment applications. 

  • Support restructuring initiatives as required as they relate to mold processes, tooling and validation of associated processes.



  • Ensure that injection molding projects are properly planned, prioritized and managed to facilitate completion with goals and objectives.

  • Staff and develop team comprised of directly and indirectly reporting chains to consistently achieve and exceed shared objectives. 

  • Develop robust talent within team for future growth.

  • Actively drive culture of ownership and encouragement through effective goal alignment and establishment of clear expectations and accountability.

  • Guide mold team by identifying all internal and external stakeholders and establishing alignment through collaboration that meet business needs.

  • Promote collaboration and teamwork with all departments by open communication and timely coordination.

  • Continuously improve internal systems/processes to ensure limited resources are utilized efficiently.

  • Develop product knowledge to help ensure customer needs are fulfilled by identifying and meeting all critical quality attributes.



  • Develop And execute molding strategic plan with key elements including capacity, business continuity, technology and profitability.

  • Author or drive capital projects for new equipment as appropriate.

  • Collaborate with Design Engineering to transfer robust products from R&D with highly capable Molding/Manufacturing processes.

  • Identify and implement new technology to improve quality, consistency, and resource utilization.

  • Lead collaboration with other departments to ensure best practices are identified and leveraged.



  • Support preparation of annual capital budget and oversee spending to meet commitments.

  • Support Cost Improvement Projects (CIPs) project planning and tracking to meet shared financial objectives.

  • Management department within targeted budget, projections, turnover and other goals as established.



  • Interface with product engineering to design and develop new or modified products.

  • Interface with manufacturing and Innovation department to develop new tooling and machines.

  • Coordinate, specify build, validate/re-validate, and troubleshoot machinery.

  • Consult with and work on category project teams as needed.  Participate in project review.  Write progress reports on projects.  Conduct design interviews.

  • Coordinate or participate as technical lead for manufacturing transfer of new products, indulging manufacturing trials or existing products.

  • Train personnel such as other technicians and set-up personnel in the use of new equipment, processes and documentation.

  • Design and execute process capability studies for processes that require it.

  • Aid in creating cost and feasibility studies.

  • Adhere to and ensure the compliance of Knapp’s Required Values, ISO certification requirements and all company policies, procedures and housekeeping standards.


SPECIALIZED SKILLS AND OTHER REQUIREMENTS (Additional preferred or required qualifications)

  • Minimum of 10 years of previous experience in related field (i.e. medical device manufacturing & assembly, plastic injection molding, plastics, automation).

  • Preferred medical device manufacturing and experience including transferring products from design to manufacturing.

  • Ability to troubleshoot and repair IMM ancillary hardware (specifically electrical and mechanical).

  • Must have demonstrated ability and experience to balance multi-task multiple engineering projects and programs in support of internal customers.

  • Expert understanding of polymer materials properties and the practical application of these principles in establishing robust manufacturing processes, troubleshooting and consulting with R&D on material selection.

  • Must have working knowledge of Microsoft Office and ERP systems.

  • Must be able to apply engineering concepts through disciplined approaches, original thinking, cause and effect, and ingenuity to solve problems.

  • Six Sigma certification is highly desirable.

  • RJG Mast Molder I, II, and III certifications.

  • Stage Gate Process

  • 8D problem solving

  • KT Analysis/Root Cause Analysis


Minimum Education & Experience Requirements


  • BS in Polymer and Plastics Engineering

  • 10-15 years in Progressive Plastic Processing & Project Management


Analytical Skills/IT

  • Process optimization

  • Scheduling production and forecasts via Excel and/or Word documents



Manufacturing Knowledge

  • Identify and correct molding defects

  • Identify and correct molding machine problems (electrical, hydraulic and mechanical).

Required Values

  • Considers multiple factors (Safety, Quality, Delivery, Cost & Inventory) when making recommendations/decisions.

  • Demonstrates high levels of positive energy and enthusiasm and a willingness to take on new challenges, responsibilities and assignments - strives to go beyond what is expected.

  • Projects a professional image in appearance, communication, and behavior even during times of stress, instills trust and is open, honest and approachable.

  • Seeks and takes advantage of opportunities to learn from others and share own knowledge so others may benefit.

  • Involves and informs others as appropriate in identifying issues, problems, opportunities and developing solutions.

  • Acts and communicates in an ethical and truthful manner, leading by example and earning the respect and trust of co-workers, customers, and other stakeholders.

  • Effective problem solving and critical thinking skills.


Working & Environmental Demands

  • Frequently works extended hours (10+ per day).

  • Occasionally required to work weekends as company needs demand.

  • Infrequently exposed to moving machinery such as forklifts.

  • Frequently exposed to loud noise from forklifts and machinery.

  • Occasionally exposed to temperature extremes in the warehouse.


Physical Demands


  • Peripheral Vision-ability to observe an area that can be seen up and down or the left and right while eyes are fixed on a given point.

  • Depth Perception – Three-dimensional vision, ability to judge distances and spatial relationships.

  • Colour Vision – the ability to distinguish objects based on the wavelengths of light they reflect, emit or transmit for detecting and differentiating between objects.



  • Occasionally lift and/or move up to 50 pounds.



  • Infrequently front carry up to 40 pounds.


Pushing and Pulling

  • Pushing/Pulling: Static Pushing and Pulling (Frequently) 25-pound force required to initiate box movement.


Ambulatory Activity

  • Standing/Walking (Infrequently) on variable surfaces throughout entire shift in the facility.

  • Step up/down from 12-40” heights to reach products at variable heights in warehouse

  • Ability to sit for extended periods of time


Repetitive Movement

  • Repetitive use of hand/grasping: (infrequently) Light to forceful manipulating/grasping of product, carts, doors.

  • Repetitive forward bending stand: (infrequently) Up to 32 inches in front of body at floor to 60” heights while reaching for product.

  • Forward bending standing: (Occasionally)

  • Reaching for and grabbing product for sorting (infrequently)

  • Squatting/Stooping/Kneeling: (infrequently) To as low as ground level while picking/stocking product.

Work Authorization/Security Clearance

Knapp Mfg., Inc. & Air Logic requires that all employees be legally authorized to work in the United States, and it abides by all laws that prohibit the employment of undocumented foreign nationals. Any person employed by the company must complete the Federal Employment Eligibility Verification Form (I-9) within three days of hire and will be entered into the Federal E-Verify system.


EEO Statement

It is the policy of Knapp Mfg., Inc. & Air Logic to provide Equal Employment Opportunity (EEO) to all persons regardless of age, color, national origin, citizenship status, physical or mental disability, race, religion, creed, gender, sex, sexual orientation, gender identity and/or expression, genetic information, marital status, status with regard to public assistance, veteran status, or any other characteristic protected by federal, state or local law. In addition, Knapp Mfg., Inc. & Air Logic will provide reasonable accommodations for qualified individuals with disabilities.



The above statements are intended to describe the general nature of work performed by employees assigned to this position. They are not intended to be construed as a complete list of all job duties performed by persons in the position.


Management reserves the right to revise or amend duties at any time as the needs of the company and requirements of the job change. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of this job.


This will acknowledge that I have read and understand the requirements and duties of the job. I further acknowledge that I can perform the essential duties listed and that I possess the knowledge, ability, skills, education, experience and other requirements as stated above.



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Employee Signature                                                                Date



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Witness Signature                                                                   Date