Foaming Process Engineer

Job Summary

Serve as a technical expert in foaming processes, responsible for developing and optimizing PU foam production for components such as seating and acoustic parts to meet quality, customer, and cost targets. This role requires strong expertise in foam chemistry, mold thermodynamics, and simulation tools, together with bilingual communication skills (English/Mandarin) preffered to support global collaboration and cross‑functional alignment.

Key Responsibilities

1. Process Development

• Define and refine foaming parameters (e.g., mix ratio, curing time) through DOE to achieve high first‑pass yield.

• Use simulation tools to optimize mold design, including venting and temperature control, for stable foam quality.

1. Mold & Equipment

• Validate new molds through trial builds and recommend improvements to achieve robust thermal balance.

• Optimize process windows and equipment settings on foaming lines to reach target overall equipment effectiveness.

1. Quality & Cost

• Apply statistical process control and capability analysis on key characteristics such as density to maintain consistent performance.

• Lead material and formulation optimization to reduce cost while meeting product and process requirements.

1. New Project Support

• Provide DFM input during early program phases, participate in risk analyses, and support product and process approval activities.

1. Continuous Improvement

• Introduce automation solutions such as robotic demolding and inline measurement and lead structured improvement projects (e.g., Six Sigma).

1. Collaboration & Training

• Address customer and internal concerns with clear technical reports and corrective actions, and train teams on operating procedures and safety/chemical‑handling requirements.

Qualifications

• Education: Bachelor’s degree in Chemical Engineering, Polymer Science, or a closely related discipline.

• Experience: 3+ years in foaming or related polymer processes within a manufacturing environment; experience with demanding quality standards is required.

• Certifications: Six Sigma Green Belt and relevant foaming or simulation certifications preferred.

• Skills:

Proficient with foaming simulation and statistical analysis tools; able to collaborate bilingually across regions.

Deep understanding of foam chemistry, including blowing‑agent behavior and cure/gel time control.

• Attributes: Strong analytical and hands‑on problem solver who can operate effectively in fast‑paced production settings.

Additional Information

• Willingness to support extended hours during trials, start‑ups, or critical production events.

• Role involves handling chemical materials; appropriate PPE and strict adherence to safety procedures are required.

• Position includes post‑hire training on customer‑specific specifications and standards.