Staff Engineer Injection Molding

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Staff Engineer - Molding

Johnson & Johnson is hiring for a Staff Engineer, Injection Molding. This position will be located in Limerick, Ireland.

Position Summary

The Staff Engineer - Molding is responsible for providing technical leadership and engineering support for contact lens molding and associated manufacturing systems. The role drives equipment reliability, molding process optimization, tooling strategy, new product introduction (NPI), and continuous improvement initiatives while ensuring compliance with safety, quality, and operational performance requirements. The position serves as a key technical interface between Manufacturing, R&D, Optical Tooling, Process Engineering, Automation, and external suppliers.

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Key Responsibilities

Mold Tooling Development and Vendor Management

• Tooling project and Vendor management to include tooling budgets, timelines, project milestones from concept to commercial. Selecting tooling suppliers and vendors issuing RFQs or URSs. Coordinate Design Reviews and Factory Acceptance Tests
• Support mold design, mold modifications, mold validation, and tooling lifecycle management.
• Manage mold flow simulations to predict and prevent design flaws and part defects.
• Create or review detailed 3D CAD models and technical drawings for components and tooling, specify technical requirements including hot runner systems and gating strategies.
• Assess tooling requirements for existing and future contact lens products, including new lens platforms and stabilization designs.
• Coordinate offline tooling activities and external vendor work related to molds, inserts, and core components.
• Partner with Optical Tooling and R&D teams to define tooling requirements for development and manufacturing programs.

Molding Process Engineering

• Provide technical ownership and engineering support for injection molding equipment, molds, inserts, cores, and associated automation systems.
• Investigate and resolve molding, tooling, process, and equipment performance issues impacting quality and production output.
• Lead root cause investigations and implement corrective actions to improve process robustness and manufacturing performance.
• Support troubleshooting of molding equipment, robotics, vacuum systems, temperature control systems, sensors, shutters, and ancillary equipment.

New Product Introduction (NPI) and R&D Support

• Collaborate with R&D and manufacturing teams to industrialize new contact lens technologies and manufacturing processes.
• Evaluate manufacturing implications of new product designs and tooling strategies.
• Participate in recurring R&D operational reviews and cross-functional technical forums.
• Support prototype, pilot, and commercial implementation activities.

Continuous Improvement and Operational Excellence

• Identify opportunities to improve throughput, yield, reliability, and operational efficiency.
• Analyze manufacturing losses, equipment downtime, and quality issues to drive sustainable improvements.
• Support capacity planning and future manufacturing investments.
• Develop engineering solutions that improve operational performance and reduce manufacturing risk.

Safety, Quality, and Compliance

• Champion safe work practices and engineering controls within molding operations.
• Lead or contribute to safety assessments, risk evaluations, and continuous safety improvement activities.
• Develop and maintain technical documentation, procedures, and training materials.
• Ensure engineering activities comply with company standards and regulated manufacturing requirements.

Cross-Functional Collaboration

• Partner with Manufacturing Operations, Process Engineering, Automation, Maintenance, Quality, R&D, and Optical Tooling organizations.
• Work with global engineering teams and external suppliers to support tooling, equipment, and technology projects.
• Provide technical guidance and subject matter expertise to production and engineering teams.

Key Stakeholders

• R&D Operations Engineering Team
• Molding Operations and Manufacturing Teams
• Optical Tooling Organizations
• Process and Automation Engineers
• Quality and EHS Functions
• External Tooling and Equipment Suppliers
• Global Vision Care Engineering Teams

Typical Deliverables

• Molding equipment and tooling improvement projects
• Root cause investigations and corrective action plans
• Mold qualification and validation activities
• Safety and risk assessment documentation
• Engineering standards, procedures, and work instructions
• Technical evaluations supporting NPI and capacity expansion initiatives

Core Competencies

• Injection molding process and tooling engineering
• Problem solving and root cause analysis
• Manufacturing systems troubleshooting
• Process optimization and continuous improvement
• Technical project leadership
• Cross-functional collaboration
• Product industrialization and NPI support
• Safety and risk management

Required Skills:

Preferred Skills:

The anticipated pay range for this position, in the primary posting location, is:

The anticipated pay ranges for additional locations are:

Benefits:

In addition to base pay, we offer the following benefits*: an annual bonus with set target (% of pay) depending on pay grade / location, where the actual amount is based on the employees’ and companies’ performance of the previous calendar year, or sales commissions. Moreover, we offer vacation days, parental leave for a minimum of 12 weeks, bereavement leave, caregiver leave, volunteer leave, well-being reimbursement, programs for financial, physical and mental health. We also offer service anniversary and recognition awards, and subject to the terms of their respective plans, employees - and in some location’s eligible dependents - can participate in several insurance plans. For more information, visit Employee benefits | Supporting well-being & career growth | Johnson & Johnson Careers.

*This is for informative purposes only. Amounts and actual benefits may vary by location and are subject to change.