Responsibilities
1. Process Development and Optimization
Process Solution Design: Based on product drawings, BOM lists, and customer quality requirements, combined with injection molding material characteristics (such as PP, ABS, PC, PA, POM, etc.), develop a reasonable injection molding process solution, clarifying key process parameters such as injection pressure, temperature, speed, holding time, and cooling time;
Process Parameter Optimization: For product defects occurring during production (such as shrinkage, flash, bubbles, weld lines, deformation, color difference, short shots, etc.), adjust process parameters through experimental verification and data analysis to optimize the forming solution and improve product yield and production efficiency; meanwhile, focus on cycle time optimization and material loss reduction to achieve cost reduction, balancing process economy and stability.
New Material Process Adaptation: Cooperate with R&D or procurement departments to conduct new material trial molding and process validation, establish a new material injection molding process parameter library, and ensure the smooth application of new materials in mass production.
Process Cost Control: On the premise of ensuring product quality, optimize process parameters to reduce material loss, shorten forming cycles, and reduce energy consumption, achieving cost reduction and efficiency improvement goals.
2. Production Process Control
Process Execution Supervision: Supervise the execution of injection molding process parameters during workshop production, check whether operators strictly follow the work instructions, and promptly correct non-compliant operations.
First-Article and Patrol Inspection Confirmation: Participate in first-article inspection before mass production to confirm process parameter adaptability and product quality compliance; conduct regular process patrol inspections of products during production to promptly identify and handle process fluctuations.
Production Exception Handling: For process-related anomalies during production (such as recurring product dimensional deviations and appearance defects), respond quickly and develop solutions to minimize production downtime.
Process Stability Maintenance: Establish a process parameter monitoring mechanism, record key process data, and analyze process fluctuation patterns; collaborate with the quality department to implement SPC (Statistical Process Control) and use control charts and other tools to identify abnormal parameter fluctuations, taking preventive measures to ensure stable production processes; conduct regular process parameter audits to ensure strict compliance with process specifications and reduce quality risks caused by human operation.
3. New Product Introduction and Trial Molding
Trial Molding Plan Development: Participate in new product mold reviews, conduct Design for Manufacturability (DFM) evaluation, and propose mold structure optimization suggestions from a process perspective (such as gate location, cooling system, vent design, etc.) to reduce production risks; based on mold structure and product characteristics, develop trial molding plans and trial molding process solutions, clarifying trial molding processes, parameter settings, and inspection focuses; for new projects, synchronously plan key nodes of the APQP development process to ensure trial molding work connects with OTS sample delivery, PPAP signing, and other requirements.
Trial Molding Process Implementation: Lead or cooperate in trial molding work, track the entire trial molding process, and record trial molding data (such as process parameters, product defects, mold issues, etc.), and analyze and summarize trial molding results.
Trial Molding Problem Rectification: For product defects and unreasonable mold aspects found during trial molding, propose process optimization or mold modification suggestions, and cooperate with the mold department to complete rectification until products meet mass production requirements.
Mass Production Process Solidification: After new product trial molding is qualified, solidify mass production process parameters, prepare formal technical documents such as work instructions and process cards, and provide technical support for mass production.
4. Process Documentation Preparation and Management
Technical Documentation Preparation: Prepare standardized technical documents such as injection molding process cards, work instructions (SOP), first-article inspection standards, and process parameter tables;
Process Data Recording and Analysis: Establish a process data ledger, record process parameters, product yield, material loss, and other data during production, and conduct regular statistical analysis to provide data support for process optimization and production decisions.
5. Equipment and Mold Process Adaptation Management
Equipment Process Adaptation: Based on product process requirements, select appropriate injection molding machines (such as tonnage, screw type, brand adaptability; common brands include Haitian, Sumitomo, Fanuc, Engel, etc.), and cooperate with the equipment department to complete injection molding machine process-related debugging and maintenance work; develop preventive maintenance plans for injection molding machines, auxiliary machines, and molds, guide daily maintenance execution, and reduce fault downtime;
Mold Process Optimization: Combined with injection molding process characteristics, propose optimization suggestions for mold gates, runners, cooling systems, etc., to improve mold forming stability and production efficiency; participate in mold daily maintenance process guidance work.
Auxiliary Equipment Process Matching: Guide operators to correctly use auxiliary equipment such as mold temperature controllers, dryers, and robots to ensure auxiliary equipment parameters match injection molding process parameters and ensure smooth production.
6. Quality Improvement and Problem Solving
Quality Defect Analysis: For injection molding product quality issues found through customer complaints or inspections, use tools such as the Seven QC Tools, Pareto charts, fishbone diagrams, and 8D reports to analyze the process causes of defects, develop and implement corrective and preventive measures; lead non-conforming product analysis meetings to drive issue closure; participate in internal and customer audits, provide injection molding process-related technical support, and address quality-related audit issues.
Quality Improvement Project Advancement: Lead or participate in injection molding product quality improvement projects, work with quality, production, and other departments to implement process optimization measures, and continuously improve product quality stability.
Quality Standard Communication: Communicate injection molding product quality standards and process requirements to production operators and inspectors, improve overall quality awareness, and ensure effective implementation of quality standards.
7. Team Training and Technical Support
8. Cross-department Collaboration and Other Work
Requirements
1. Over 5 years of work experience, familiar with the automotive electronics industry;
2. Proficient in injection molding process principles, familiar with the characteristics and forming process requirements of different injection molding materials (PP, ABS, PC, PA, POM, etc.); understand relevant knowledge of polymer rheology, and able to precisely match materials with process parameters.
3. Rich experience in injection molding process debugging and optimization, able to quickly resolve process issues and product defects during production; master full-process trial molding management skills, able to independently complete new mold trial molding and process parameter development.
4. Familiar with the working principles and process adaptation requirements of injection molding machines, molds, and auxiliary equipment, understand mainstream injection molding machine brand operating systems, able to cooperate in completing equipment debugging, maintenance, and automation integration; possess basic knowledge of mold structure, able to propose mold optimization suggestions from a process perspective.
