Sr. Engineer - Process Engineering

We are seeking a highly competent and technically strong Process Engineer with proven expertise in end-to-end electronics manufacturing processes, including SMT, PTH, Box Build, Electro-Mechanical Assembly, Cable Harness, Mechanical Integration, and FAIR validation activities.

The ideal candidate will demonstrate strong ownership in process establishment, validation, troubleshooting, yield improvement, process control, and continuous improvement initiatives. The role requires the ability to independently drive manufacturing excellence in a high-mix, low-volume, and complex product manufacturing environment.

• Own complete process engineering activities from NPI builds through mass production stabilization.
  
• Define, validate, optimize, and sustain robust manufacturing processes.
  
• Lead process readiness reviews prior to product release into production.
  
• Establish manufacturing process capability aligned with customer requirements and internal quality standards.
  
• Drive process standardization and manufacturing best practices across production lines.
  

• Develop, validate, and optimize SMT processes including:
  
  • Solder Paste Printing
    
  • SPI (Solder Paste Inspection)
    
  • Pick & Place Programming
    
  • Reflow Soldering
    
  • AOI (Automated Optical Inspection)
    
  • X-Ray Inspection
    
• Establish process windows and optimize machine parameters.
  
• Perform thermal profiling and solder joint reliability validation.
  
• Analyze solder-related defects and implement permanent corrective actions.
  
• Improve First Pass Yield (FPY), Overall Equipment Effectiveness (OEE), and manufacturing efficiency through process optimization.
  

• Develop and control manufacturing processes for:
  
  • Through-Hole Assembly
    
  • Manual Component Insertion
    
  • Wave Soldering
    
  • Selective Soldering
    
  • Hand Soldering Operations
    
• Optimize process parameters including:
  
  • Flux Application
    
  • Preheat Settings
    
  • Conveyor Speed
    
  • Solder Pot Temperature
    
  • Dwell Time
    
• Reduce soldering defects through process characterization and validation.
  
• Ensure compliance with IPC workmanship and soldering standards.
  

• Define complete assembly methodologies and process flows for box-build and system integration products.
  
• Establish process sequencing, takt time requirements, tooling strategies, and assembly controls.
  
• Drive manufacturing readiness for final assembly and system integration builds.
  
• Ensure compliance with product configuration requirements and customer specifications.
  
• Support functional integration and manufacturing process validation activities.
  

Provide technical leadership in:

• Mechanical drawing interpretation
  
• GD&T application and tolerance analysis
  
• Torque control methodologies
  
• Fastening systems and assembly controls
  
• Press-fit operations
  
• Adhesive dispensing processes
  
• Bonding and sealing applications
  
• Gasket installation processes
  
• Fixture validation and qualification
  
• Mechanical tolerance stack-up analysis
  

Drive electro-mechanical assembly optimization with focus on precision, repeatability, product quality, and defect prevention.

• Lead FAIR (First Article Inspection Report) preparation and validation activities.
  
• Develop and maintain:
  
  • Process Flow Diagrams
    
  • PFMEA
    
  • Control Plans
    
  • SOPs
    
  • Work Instructions
    
  • Validation Reports
    
  • Process Qualification Documents
    
• Manage Engineering Change Notices (ECN) and Engineering Change Orders (ECO).
  
• Ensure compliance with customer documentation requirements and quality standards.
  

Lead structured problem-solving initiatives using:

• 8D Methodology
  
• 5 Why Analysis
  
• Fishbone (Ishikawa) Analysis
  
• Pareto Analysis
  
• Statistical Process Control (SPC)
  
• Process Capability Analysis
  

Drive measurable improvements in:

• Yield Performance
  
• Defect PPM Reduction
  
• Cycle Time Optimization
  
• Throughput Improvement
  
• Process Stability
  
• Manufacturing Cost Reduction
  

• Provide technical leadership during prototype, pilot, and production ramp-up builds.
  
• Conduct DFM (Design for Manufacturability) and DFA (Design for Assembly) reviews.
  
• Identify manufacturing risks proactively and implement mitigation plans.
  
• Support seamless transfer from engineering builds to production release.
  
• Collaborate closely with Design, Quality, Production, Supply Chain, and Customer teams.
  

Drive continuous improvement initiatives including:

• Lean Manufacturing
  
• Kaizen Activities
  
• Line Balancing
  
• Capacity Optimization
  
• Waste Elimination
  
• Poka-Yoke Implementation
  
• 5S Deployment
  
• Visual Management Systems
  

Promote a culture of operational excellence and process discipline.

• B.E./B.Tech/Diploma in:
  
  • Electronics & Communication Engineering
    
  • Electrical & Electronics Engineering
    
  • Manufacturing Engineering
    
  • Mechanical Engineering (with Electronics Manufacturing experience)
    

• 2–5 years of hands-on experience in Electronics Manufacturing Services (EMS).
  
• Experience in high-mix, low-volume manufacturing environments preferred.
  

Strong working knowledge and hands-on experience in:

✔ SMT Process Engineering

✔ PTH / Wave Soldering / Selective Soldering

✔ Box Build Assembly

✔ Cable Harness Assembly

✔ Electro-Mechanical Integration

✔ Mechanical Assembly Controls

✔ FAIR Documentation & Validation

✔ Process Qualification & Validation

✔ IPC Standards & Workmanship Requirements

✔ Root Cause Analysis & Troubleshooting

✔ Yield Improvement & Process Optimization

✔ Engineering Documentation & Change Management

Experience in one or more of the following industries:

• Aerospace Electronics Manufacturing
  
• Defense Electronics
  
• Medical Electronics
  
• Industrial Automation Electronics
  
• High-Reliability Electronics Manufacturing
  

Exposure to the following standards is highly preferred:

• AS9100
  
• IPC-A-610
  
• IPC J-STD-001
  
• IPC/WHMA-A-620
  
• Customer-Specific Quality Requirements
  

• Strong Technical Ownership
  
• Multi-Process Manufacturing Expertise
  
• Analytical & Problem-Solving Skills
  
• Data-Driven Decision Making
  
• Cross-Functional Collaboration
  
• Execution Excellence
  
• Process Discipline
  
• Continuous Improvement Mindset
  
• Customer Focus
  
• Leadership & Accountability