Senior Process Development Engineer

Advantest Interconnect Solutions (AIS) is seeking a highly experienced Senior SMT Process Engineer to lead Surface Mount Technology (SMT) process development, optimization, and manufacturing stability initiatives at our Fremont, California facility.

This role is responsible for establishing world-class SMT manufacturing processes that deliver predictable quality, yield, throughput, and reliability while supporting advanced semiconductor test interface products and complex PCB assemblies. The position serves as the technical owner for SMT process capability and continuous improvement, working closely with Engineering, Quality, Production, Supply Chain, and our Taiwan manufacturing team to standardize and scale best practices across AIS's global assembly operations.

The successful candidate will be a hands-on manufacturing expert capable of solving complex process challenges, improving operational performance, and supporting new product introductions from prototype through high-volume production.

• Serve as the technical owner for all SMT manufacturing processes within the Fremont facility.

• Develop and maintain robust process controls to ensure stable, repeatable production performance.

• Monitor and improve key manufacturing metrics, including:

• First-Pass Yield (FPY)
• Defects Per Million (DPM)
• Overall Equipment Effectiveness (OEE)
• Scrap and Rework
• Cycle Time
• Throughput

• Establish process capability targets and statistical control methodologies.

• Lead root-cause investigations using structured problem-solving methodologies.

• Develop, qualify, and implement new SMT assembly processes, materials, and equipment.

• Optimize:

• Solder Printing
• Component Placement
• Reflow Soldering
• Automated Optical Inspection (AOI)
• Solder Paste Inspection (SPI)
• Selective Soldering
• Conformal Coating (where required)

• Drive process improvements focused on quality, capacity, automation, and cost reduction.

• Implement Lean Manufacturing, Six Sigma, and Design for Manufacturing/Assembly (DFM/DFA) principles.

• Provide manufacturing expertise during design reviews and product development.

• Partner with Design Engineering, Applications Engineering, and Operations teams to ensure manufacturability.

• Develop process validation plans and qualification criteria for new products.

• Support prototype builds, pilot runs, and production ramp activities.

• Partner closely with AIS's Taiwan assembly operations to establish common process standards and best practices.

• Drive cross-site process harmonization and knowledge transfer.

• Participate in global manufacturing reviews and continuous improvement initiatives.

• Support benchmarking and replication of successful process improvements across AIS assembly locations.

• Define equipment requirements and process technology roadmaps.

• Support selection, installation, qualification, and optimization of SMT manufacturing equipment.

• Collaborate with Maintenance and Equipment Engineering teams to maximize uptime and process capability.

• Evaluate emerging SMT technologies and automation opportunities.

• Ensure compliance with IPC standards and customer-specific manufacturing requirements.

• Support customer audits, internal audits, and corrective action activities.

• Lead PFMEA, Control Plan, and process validation activities.

• Drive a culture of operational excellence and continuous quality improvement.

• Provide technical leadership to manufacturing engineers, technicians, and production personnel.

• Develop standardized work instructions, process documentation, and training materials.

• Mentor junior engineers and help build AIS's long-term manufacturing capabilities.

• Minimum 10 years of progressive experience in SMT manufacturing and process engineering.

• Proven experience supporting high-complexity PCB and PCBA manufacturing environments.

• Strong expertise in:

• SMT process development
• Solder paste printing
• Placement optimization
• Reflow profiling
• AOI/SPI systems
• Statistical Process Control (SPC)
• Root cause analysis

• Experience implementing Lean Manufacturing and Six Sigma methodologies.

• Demonstrated success improving yield, quality, and manufacturing efficiency.

• Strong data analysis and problem-solving capabilities.

• Ability to travel internationally, including periodic travel to Taiwan.

• Experience in semiconductor test, ATE, high-performance computing, networking, or other advanced electronics manufacturing environments.

• Six Sigma Green Belt or Black Belt certification.

• Experience with MES systems, Industry 4.0 initiatives, and manufacturing automation.

• Knowledge of IPC-A-610, J-STD-001, and related industry standards.

• Experience supporting global manufacturing organizations and multi-site operations.

• Familiarity with advanced packaging, high-density interconnect (HDI) assemblies, and high-reliability electronics.

During the first 12-18 months, the Senior SMT Process Engineer will be expected to:

• Establish Fremont as a benchmark SMT operation within AIS.

• Improve first-pass yield, cycle time, and throughput.

• Reduce process variation and defect opportunities.

• Standardize SMT processes between Fremont and Taiwan where appropriate.

• Support capacity growth and new product introductions.

• Drive automation and continuous improvement initiatives that improve scalability and operational performance.