Foaming Process Engineer

Job Summary

As a technical expert in foaming processes, responsible for developing and optimizing PU foam production (seats, acoustic parts) to meet IATF 16949, customer CSR, and cost targets. Requires expertise in foam chemistry, mold thermodynamics, and simulation tools (FoamSim), with bilingual (English/Mandarin) skills to drive global technical alignment and cross-functional collaboration.

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Key Responsibilities

1. Process Development

- Define foaming parameters (mix ratio, curing time) via DOE to achieve FPY98%.

- Optimize mold design (venting, temperature control) using FoamSim simulations.

2. Mold & Equipment

- Validate new molds (T0/T1 trials) and improve thermal balance design.

- Optimize equipment settings (high-pressure machines) to achieve OEE80%.

3. Quality & Cost

- Implement SPC control charts (density Cpk1.67) and drive material substitution for cost savings.

4. New Project Support

- Conduct DFM analysis during APQP, review PFMEA, and support PPAP submissions.

5. Continuous Improvement

- Deploy automation (robotic demolding, inline density checks) and lead Six Sigma projects.

6. Collaboration & Training

- Resolve customer complaints with technical reports and train teams on SOPs/MSDS compliance.

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Qualifications

- Education: Bachelor’s degree in Chemical Engineering, Polymer Science, or related field.

- Experience: 3+ years in foaming processes; automotive experience required.

- Certifications: Six Sigma Green Belt, FoamSim certification preferred.

- Skills:

- Proficient in FoamSim, Minitab; bilingual for global collaboration;

- Deep knowledge of foam chemistry (blowing agent kinetics, gel time control).

- Attributes: Analytical problem-solver, adaptable to fast-paced environments.

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Additional Information

- Flexibility for extended hours during trials;

- Chemical exposure (isocyanates); PPE (respirators, coveralls) required;

- Customer-specific training (e.g., BMW GS98000) provided.

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