Laboratory Engineer

Role Summary

The Foaming Process Quality Engineer serves as a key leader for foaming process and quality standards. This role is responsible for optimizing polyurethane (PU) foam production for automotive components such as seats and acoustic parts while ensuring compliance with IATF 16949 and customer-specific requirements. The position requires a blend of expertise in foam chemistry, quality tools, and bilingual communication to drive defect reduction and cross-functional success.

Key Responsibilities

Process Stability and Optimization

• Monitor critical foaming parameters including mix ratios and curing times.
• Optimize formulations using Design of Experiments (DOE).
• Maintain Statistical Process Control (SPC) charts for density and hardness with a Cpk target of ≥1.33.

Defect Resolution and Quality Control

• Lead root cause analysis (5Why) for defects like voids or cracks and implement corrective actions.
• Coordinate Material Review Board (MRB) meetings for the containment of non-conforming products.
• Track process data through Manufacturing Execution Systems (MES) to develop quality alerts.

Material Validation and Technical Support

• Test and validate new materials, including low-VOC and bio-based polyurethane.
• Support PPAP submissions and host customer audits for foaming processes.
• Resolve technical complaints regarding odor issues or NVH performance through detailed reports.

Continuous Improvement

• Drive Lean Six Sigma projects focused on material efficiency and cycle time reduction.
• Implement automated testing equipment, such as density gauges, to modernize quality checks.

Qualifications:

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

Experience: At least 5 years of experience in foaming processes or quality within the automotive industry.

Technical Skills: Deep knowledge of foam chemistry, blowing agent kinetics, and gel time control.

Language (Preferred, not required) : Bilingual proficiency in English and Mandarin for technical documentation and global alignment.

Software: Proficiency in foaming simulation tools (FOAMSIM), Minitab, and Power BI.

Preferred Credentials

• Six Sigma Green or Black Belt certification.
• IATF 16949 internal auditor certification.

Physical Requirements and Environment

• Exposure to chemicals such as isocyanates is expected.
• Must be comfortable wearing required PPE, including respirators and coveralls.
• Flexibility is required for project-driven schedules and extended hours during trial runs.