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Coating Process Technical Leader

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Date: Nov 13, 2022

Location: Hefei, AH, CN, 230011

Company: Corning

Day to Day Responsibilities:

  • Work/liaise with development, engineering, plant, suppliers and commercial to run experiments and development of new products, processes, technology and equipment
  • Lead and review experimentation, process development, qualification, red-flag testing, new technology transfer, capacity expansion, process improvement and changes to existing processes
  • Evaluate potential gain from opportunities in raw materials, consumables, equipment, measurements, AOI, handling, cleaning, surface preparation, automation, the environment and systems
  • Apply DMAIC and engineering principles to understand the root cause and eliminate defects
  • Design experiments, process development and qualification with DOE for new process, materials, AR stack design, engineering changes, equipment, measurements and vendors
  • Collaborate with development and manufacturing in building bench strength, technical depth, and advancing fundamental understanding of AR & ETC coatings on glass
  • Influence key decision-makers and stakeholders on AR & ETC coating technology process optimization and deliver transformational improvements on next generation capabilities to manufacturing
  • Lead or support scale-up and new coatings technology transfer to manufacturing plants and contract manufacturers
  • Provide technical consultation and subject matter expertise in glass AR & ETC coating troubleshooting support and process performance improvement including yield, capability, cost reduction, capacity expansion, etc.
  • Lead problem solving and process improvement using structured problem-solving methods such as MEE, KT, Designed of Experiment, or DMAIC.
  • Lead/support development of AR & ETC technology roadmap  

 

Day to Day Responsibilities:

  • Engage stakeholders to determine product and process requirements for new product introduction (NPI)
  • Leverage 3D CAD, analytical tools, simulation, modeling, digital transformation and data analytics to foresee and mitigate risks, minimize process tuning/FAI/downtime and advance capabilities
  • Support assessments and the qualification of contract manufacturers for AR & ETC coatings through engineering process capabilities, equipment, metrology and quality performance assessments
  • Manage and coordinates a cross-function project team for coating machine installation, debugging and initial operation of new equipment and systems using project management tools and best practices
  • Lead/support equipment design and development from concept, fabrication to final qualification
  • Conceptualize and test cost-effective glass handling automation - Incorporate and champion design for safety in all equipment and process improvements development projects/activities. Ensure safety requirements are met from design through construction, process start-up to handover to operations
  • Estimate budget, capacity, utilization and provide technical support for NPI upon request
  • Analyze equipment and process design for function, safety, repeatability, cost-effective operation, ease of maintenance and capital efficiency
  • Ensure that equipment, consumables and tooling meet targets for lifetime, cost and cycle time
  • Support equipment design and development from concept, fabrication to final qualification
  • Provide communication updates to colleagues and leadership team - Facilitate the design of manufacturing processes and equipment layouts
  • Identify low-hanging fruits, prioritize opportunities, capture quick-wins and share remaining ideas - Promote and support digital transformation in process, equipment design and improvements
  • Document best practices, intellectual assets and share experience and lessons learned via RTRs
  • Identify technical skills and building blocks to establish a world-class Center of Excellence (COE) in automotive glass AR & ETC coating
  • Hire, develop, mentor, grow and retain talent within division engineering coating team

 

Education & Experience

  • BS/MS/PhD majoring in Physics, Materials Science, Optics, Optoelectronics, Chemical Engineering, Applied Chemistry, Ceramic Engineering or related fields
  • ≥ 10 years of solid project, industrial, engineering and manufacturing experience in glass coating processes and thin film coating processes within the automotive industry
  • ≥ 8 years of project and functional leadership experience
  • Prefer to know at least one tool of TFCalc, Macleod, Optilayer, etc.
  • Exposure to automotive parts NPI and manufacturing is a plus (for example: APQP, PPAP, IATF 16949 or Automotive Safety Testing)
  • Experience of living, studying, working abroad or extended travel outside of home country is a plus
  • Experience working for foreign multi-national corporations is a plus
  • Diversity in experience and/or background is an asset

 

Required Skills

  • Minimum 5 years hands-on process experience in a glass coating and finishing operation
  • Familiar with Magnetron Sputtering, PVD and other thin film deposition process methods
  • Familiar with Drum Coater, Batch Coater, In-Line Coater or other thin film deposition equipment
  • New coating/PVD machine installation, and or expansion experience
  • Strong academic background; able to apply scientific and engineering principles to solve problems
  • Skilled in planning and executing experiments, data collection & analysis, and refuting hypotheses
  • Analyze process data and trends for solving process or equipment problems
  • Can quickly turn manufacturing and customer requirements into detailed project and action plans  

 

Required Skills

  • Able to track and report progress effectively
  • Excel at identifying and engaging experts and key stakeholders to solve difficult technical problems
  • Solid track record of leading teams of engineers, technicians and scientists to hit project goals timely
  • Working knowledge of statistics, process control tools and change management protocols
  • Communicates well with internal customers, external suppliers, technical collaborators and operators
  • Organizes and drives work across organizational boundaries to meet deadlines and get results
  • Fluency in project management tools and techniques
  • Hands-on experiment skills, including the use of material characterization instruments
  • Analytical skills in optics, materials science, chemistry, especially related to coating, glass and ceramics
  • Good mechanical aptitude
  • Can systematically and methodically determine the root cause of PVD dots, lines, spots, stains, bright spots, scratches, shadows, chips, particles and contamination on the production floor
  • Deep understanding of quality systems, PFMEA, control plan
  • Competency in external supplier management, qualification and contract management
  • Likes to document and share lessons learned
  • Clear understanding of equipment set-up and calibration process
  • Develops clear bilingual visual work-instructions on process tuning, job change, calibration and etc.
  • Responsible for the accuracy of work performed and proactively ensures quality of work
  • Possess strong work ethic and attention to detail with excellent organizational skills
  • Ability to work with people of diverse technical and cultural backgrounds
  • Develops, coaches and mentor people
  • Experience working on one or more of the following types of process, equipment or measurements:

 

Desired Skills

  • CAD software proficiency is an asset
  • Independently operate 2.5D gauges to measure profile-of-line on parts without any straight edges
  • Knowledgeable of surface energy, cleanliness measurements, abrasives and polishing compounds
  • Exposure to glass cutting by laser and/or optics is a plus
  • Experience in locating glass edge and achieving alignment through integrated machine vision
  • Familiar with industrial safety standards (including ergonomics) and different equipment standards
  • Expertise in cleanliness and environment control of dust and particulates
  • Expertise in coating, spraying, etching, plasma cleaning technology is a plus
  • Exposure to 6-sigma, Lean, 5S, TRIZ, DMAIC, MEE and/or PQA projects is a plus
  • Hands-on experience with machine shop tools: milling machine, lathe or other fabrication machinery
  • Machinery repairs and maintenance experience is a plus