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Decoration Process Engineer, CI AGS, Hefei

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Date: Sep 18, 2021

Location: Hefei, AH, CN, 230011

Company: Corning

Requisition Number: 49901

 

Corning is one of the world’s leading innovators in materials science. For more than 160 years, Corning has applied its unparalleled expertise in specialty glass, ceramics, and optical physics to develop products that have created new industries and transformed people’s lives.

Corning succeeds through sustained investment in R&D, a unique combination of material and process innovation, and close collaboration with customers to solve tough technology challenges.

Purpose of the Position:

  • Support Auto Glass Solutions sales & profitability objectives by providing value added technical consultation, hands-on expertise support and participation in the development, engineering and manufacturing of decoration process on glass parts for automotive interior and exterior applications
  • Increase Auto Glass Solutions business competitiveness by delivering transformational process improvements and next generation capabilities in parts decoration processes/materials/equipment to manufacturing operations

Note: Decoration processes include but is not limited to screen printing, ink jet printing, spray & roll coating, transfer printing, masking, photo BM, cleaning, AOI, handling, curing, and screens & fixtures production

 

Day to Day Responsibiliteis:

 

  • Work/liaise with development, engineering, plant, suppliers and commercial to run experiments and development of new products, processes, technology and equipment for parts decoration processes
  • Evaluate decoration process requests and glass handling concepts based on experience and in-depth knowledge
  • Collaborate with development and manufacturing to advance fundamental understanding of decoration processes
  • Apply DMAIC and engineering principles to understand the root cause and eliminate defects
  • Design experiments, process development and qualification with DOEs for new decoration processes, materials, screens & fixtures design, engineering changes, equipment, measurements and vendors
  • Lead or support development of AGS parts decoration process, scale-up and new ink-printing technology transfer to manufacturing plants and contract manufacturers
  • Provide technical consultation and subject matter expertise in glass parts decoration process troubleshooting support and process performance improvement including yield, capability, cost, capacity, etc.
  • Support problem solving and process improvement using structured problem-solving methods such as MEE, KT, Designed of Experiment, or DMAIC.
  • Engage stakeholders to determine product and process requirements for new product introduction (NPI)
  • Leverage 2D/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 development of AGS parts decoration process technology roadmap which includes automation of manual processes and glass handling
  • Lead the qualification of contract manufacturers for decoration processes & equipment through engineering process capabilities, equipment, metrology and quality performance assessments
  • Identify technical skills and building blocks to establish a world-class Center of Excellence (COE) in automotive glass decoration processes
  • Problem solving and process improvement using structured problem-solving methods such as MEE, KT, Designed of Experiment, or DMAIC.
  • Coordinates decoration process equipment installation, debugging and initial operation of new equipment and systems
  • Support equipment design and development from concept, fabrication to final qualification
  • Incorporate 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
  • Provide communication updates to colleagues and leadership
  • Present ideas, plans, project status & VOC orally with visual aids or in writing
  • Facilitate the design of manufacturing processes and layout
  • 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 and intellectual assets
  • Share experience & lessons learned

 

Education & Experience  

  • BS/MS/PhD majoring in mechanical, materials, chemical, ceramic engineering or related fields
  • ≥ 5 years of solid project, industrial, engineering and manufacturing experience in glass decoration processes and in automotive industry
  • 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

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Required Skills                                                

  • Minimum 5 years hands-on process experience in a glass decoration and finishing engineering, process and/or manufacturing operations
  • 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
  • Can quickly turn manufacturing and customer requirements into detailed project and action plans
  • 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/supporting 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 materials science, chemistry, especially related to inks, glass and ceramics
  • Good mechanical aptitude and can operate CAD software proficiently
  • Can systematically and methodically determine the root cause of pin holes, ink peel-off, scratches, shadows, chips, particles, stains 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:
    • WCA and dyne value measurement
    • Abrasion cycling
    • Solar exposure reliability testing
    • PVD and/or spray coating
    • Surface cleaning (ultrasonic, brush cleaning or plasma cleaning) and wiping
    • Glass surface protection for scratch and stain prevention
    • 1:1 film lamination
    • Chemical and/or physical strengthening of glass
    • Thin glass material handling and fixtures
    • Screen making and ink mixing & testing
    • Automated cosmetic inspection and pattern recognition
    • Clean environments, tents and chambers
    • Mechanical and reliability testing, dimensional measurement and/or optical measurement
    • Automated curved surface measurement and profile-of-line measurement on curved edges
    • Laser cutting or measurement systems
    • 2.5D edge polishing and/or glass edge coating or decoration
    • Part serialization on glass and/or ceramics
    • Polishing compound and/or coolant circulation and filtration system
    • Tunnel ovens, batch ovens and/or environmental chambers
    • flat glass or thin sheet cassettes or packing / stacking with interleaf material
    • material reliability testing for automotive components
    • Semi-automatic man-machine collaborative work cells
  • Detail-oriented and performs well under pressure with limited supervision
  • Effective communication in English and in at least one of the major Asia or European languages
  • Instills trust and confidence
  • Honest and pragmatic but tactful
  • Adapts to change quickly; takes frequent changes in strides
  • Effective at managing time and competing priorities
  • Customer oriented:  manage expectations and meet / exceed customer requirements with quality results
  • Quickly develops effective work relationships and rapport with others in a new environment
  • Contributes and enriches the professional development and career experiences of others

 

Desired Skills:

  • 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
  • Exposure to equipment for thermal processes is a plus
  • Experience with facility equipment and inflammable / corrosive fluids is a plus
  • Exposure to finishing of brittle materials
  • Exposure to glass AOI systems is a plus
  • Understanding of industrial 4.0
  • Exposure to wastewater treatment and/or pollution abatement is a plus