Alcon

Through this Eric Huang shares insights on managing complex molding processes in the R&D Pilot Molding Lab, highlighting the importance of providing a stress-free environment for technicians and optimizing processes to improve quality and efficiency. He emphasizes the role of inspections, statistical monitoring and simulations in cost reduction and process optimization.

Journey in Polymer Processing and Molding

I graduated from the University of Maryland with a Ph.D. degree in Mechanical Engineering. My research focus was on polymer processing. I have been working in manufacturing and R&D environments since then. My experiences were mainly in injection molding, from molding facility build, managing mold suppliers, qualification, process development and optimization to new product development. Eleven years in the medical industry, an expert in plastic, rubber and liquid silicone molding. I also enjoyed working with people and witnessing their talents and dedication.

Creating a Stress-Free, Efficient Environment

To run a smooth operation with no hiccups. With highly complex molding activities and the highest cleanness requirement, such as no particles allowed on the tools, I need to provide a stress-free environment for our technicians. So, I limited the tooling change only once a day at maximum to allow ample time to verify the tools and avoid any possible errors. I even stack the working time from 5:00 am and end at 5:30 pm with all technicians to provide longer service time. I know that working on everything in a hurry will only delay the process.

Open-mindedness and embracing challenges are essential to aligning R&D with broader business goals.

Streamlining Molding Processes

First is inspection and process monitoring. We do cosmetic, optical and dimensional inspections and put them into statistical charts to quickly identify changes and out-of-control parameters. Then, multiple DOE studies will tell me how to optimize the process due to design changes or other factors. We also used flow simulation to optimize the part design using automation to reduce cost and improve efficiency. As always, the most important thing is to inspire our people. Maintain their passion by giving them respect and recognition.

The Future of Manufacturing

I read plastic newsletters, attend shows and listen to seminars. I think 3D printing will significantly improve mold design and process optimization. Still, the most exciting thing is that anyone can design a medical device and print out the production quality parts that can be assembled and tested with negligible cost. It will no longer be the big companies’ advantage in inventing new devices. We may even connect customers with school students to initiate design competitions.

Fostering Collaboration

Open-minded and welcoming all the challenges of collaboration. I treat other groups as our customers and will fulfill their requirements whenever possible. Also, to provide insight for improvements. Always connect practical issues with original visions to bring all the departments on the same page and make the right corrections.