SUMMARYLead, develop, and optimize manufacturing processes for circuit card assemblies (CCAs) and electronic assemblies incorporating a mix of Surface Mount (SMT) and Through-Hole (TH) technologies. Provide advanced technical expertise and leadership in the development, implementation, validation, and continuous improvement of manufacturing processes to achieve high quality, high yield, cost effectiveness, and on-time delivery.
Lead complex manufacturing engineering projects and provide technical direction for process improvement, new product introduction (NPI), capacity expansion, equipment implementation, automation, and cost reduction initiatives. Utilize advanced problem-solving, data analysis, root cause analysis, and systematic engineering methods to identify and eliminate process risks and recurring issues.
Serve as a technical resource and mentor to Manufacturing Engineers and Manufacturing Engineering support personnel. Collaborate closely with Engineering, Quality, Operations, Program Management, Supply Chain, customers, and suppliers to establish robust manufacturing processes and drive continuous improvement across the organization.
ESSENTIAL DUTIES AND RESPONSIBILITIESInclude the following. Other duties may be assigned.
- Read, interpret, and evaluate customer documentation, quality requirements, engineering drawings, specifications, and Engineering Changes to determine manufacturing requirements and potential process risks.
- Lead the design and development of complex manufacturing processes to meet product, customer, quality, cost, and delivery requirements efficiently and effectively, including:
- Determine and optimize overall Process Flow and manufacturing strategy.
- Develop and maintain detailed operator work instructions for automated and manual processes, including appropriate inspection and control points.
- Design, specify, order, and validate process tooling, including SMT stencils, wave pallets, press-fit tooling, component forming/prep tooling, jigs, fixtures, and other specialized manufacturing aids.
- Develop, optimize, and validate SMT and Through-Hole soldering profiles.
- Maintain and optimize customer Bill of Materials and manufacturing data.
- Evaluate, approve, and implement chemical materials and application processes.
- Establish and optimize critical process parameters, specifications, and process controls.
- Ensure manufacturing processes and process parameters are capable of consistently meeting product requirements and solder quality requirements in accordance with IPC-610/J-STD-001 Class 3 standards.
- Lead manufacturing engineering activities for new product introduction, including Design for Manufacturability (DFM) and Design for Assembly (DFA) reviews, process development, tooling strategy, equipment requirements, process validation, pilot builds, and production release.
- Lead complex technical investigations and root cause analysis for manufacturing, quality, and process issues. Utilize structured problem-solving methodologies such as 8D, 5-Why, Fishbone, DOE, SPC, and other appropriate analytical tools to identify permanent corrective actions.
- Provide advanced technical support to the production floor and lead cross-functional teams in resolving issues related to Man/Method/Machine/Material/Measurement/Environment.
- Monitor and analyze key manufacturing metrics, including Customer Return Rate (CRR), First Pass Yield (FPY), Scrap, cycle time, downtime, and overall equipment/process efficiency. Develop and lead improvement plans to achieve or exceed established goals.
- Identify opportunities to improve manufacturing capability, reliability, throughput, capacity, and cost through process optimization, automation, equipment improvements, and implementation of Lean Manufacturing principles.
- Lead initiatives to optimize production line balance, material flow, equipment utilization, and changeover processes to maximize throughput and minimize manufacturing downtime.
- Lead or support capital equipment selection, evaluation, installation, qualification, and implementation. Develop equipment specifications and work with suppliers to ensure equipment meets manufacturing requirements.
- Identify and implement cost-reduction opportunities through process simplification, labor optimization, material utilization, automation, tooling improvements, and other engineering solutions.
- Develop and utilize engineering data, process capability studies, statistical analysis, and other analytical methods to establish process controls and support engineering decisions.
- Lead process validation activities and establish appropriate documentation to ensure manufacturing processes are robust, repeatable, and capable of meeting product requirements.
- Provide technical leadership during major process changes, engineering changes, product transfers, capacity increases, and manufacturing line moves.
- Assist Project Engineer(s) and Program Management with capacity modeling, labor quoting, capital expenditure justification, manufacturing cost analysis, and production planning activities.
- Serve as a technical subject matter expert for SMT, Through-Hole, soldering, assembly, inspection, and other applicable electronics manufacturing processes.
- Provide technical guidance, mentoring, and training to Manufacturing Engineers, Manufacturing Engineering Assistants, and Manufacturing Engineering Technicians.
- Review and provide technical input on work instructions, process documentation, tooling designs, equipment specifications, and manufacturing methods developed by other Manufacturing Engineers.
- Lead cross-functional technical meetings and communicate project status, risks, technical issues, and recommendations to management and other stakeholders.
- Collaborate effectively with Engineering, Quality, Operations, Supply Chain, Program Management, customers, and suppliers to resolve technical issues and achieve project objectives.
- Encourage open communication, knowledge sharing, and continuous improvement within the Manufacturing Engineering department and across supporting organizations.
- Establish and promote manufacturing engineering best practices, standard processes, and lessons learned throughout the organization.
- Adhere to all safety and health rules and regulations associated with this position and as directed by supervisor.
- Comply with and follow all procedures within the company security policy.
MINIMUM REQUIREMENTS- Significant Manufacturing/Process Engineering experience in Electronics Manufacturing, including:
- Advanced knowledge of electronic components, printed circuit boards, soldering processes, materials, and chemistries used in electronics manufacturing.
- Demonstrated ability to independently design, develop, validate, and optimize complex manufacturing processes involving SMT, Through-Hole, and electronic assembly technologies.
- Demonstrated advanced knowledge of IPC-610/J-STD-001 requirements and their application to manufacturing processes.
- Demonstrated knowledge and practical application of structured problem-solving and root cause analysis methodologies.
- Demonstrated ability to analyze manufacturing data and use statistical methods, process capability, SPC, DOE, or other analytical tools to improve process performance.
- Demonstrated understanding of manufacturing capacity, labor modeling, quoting, efficiency, cost analysis, and production planning.
- Demonstrated experience leading cross-functional projects and implementing process improvements from concept through production.
- Demonstrated ability to evaluate and implement manufacturing equipment, automation, tooling, and process improvements.
- Demonstrated ability to identify manufacturing risks and develop effective preventive and corrective actions.
- Strong project management and organizational skills with the ability to manage multiple priorities and projects with limited supervision.
- Ability to effectively communicate complex technical information, both written and verbal, with suppliers, customers, peers, management, engineering personnel, and direct-labor manufacturing personnel.
- Demonstrated leadership and mentoring skills with the ability to influence and guide others without direct supervisory authority.
- Ability to make sound technical decisions independently and take ownership of complex manufacturing engineering issues.
- Bachelor's degree in manufacturing engineering, Mechanical Engineering, Electrical Engineering, Industrial Engineering, or a related technical field preferred.
- Must be a U.S. Citizen due to defense contract requirements
LANGUAGE SKILLSAbility to read, analyze, and interpret complex technical documents, engineering drawings, customer specifications, quality requirements, procedures, and regulatory standards. Ability to effectively communicate complex technical concepts and recommendations in written and verbal form to individuals at various organizational and technical levels. Ability to lead technical discussions and foster positive, productive communication among cross-functional teams.
MATHEMATICAL SKILLSAbility to apply advanced mathematical and statistical concepts to manufacturing engineering problems. Ability to calculate and analyze figures and amounts such as percentages, proportions, tolerances, yields, process capability, cycle times, capacity, labor efficiency, cost, and productivity. Ability to apply concepts of algebra, geometry, statistics, and engineering calculations.
REASONING ABILITYAbility to solve complex practical problems and deal with a variety of variables in situations where limited standardization exists. Ability to independently identify problems, evaluate alternatives, determine root causes, and develop effective engineering solutions. Ability to interpret and apply complex instructions furnished in written, oral, diagram, specification, or schedule form.
Ability to evaluate the potential impact of process changes and make sound technical decisions based on engineering principles, data analysis, risk assessment, and business requirements.
PHYSICAL DEMANDSThe physical demands described here are representative of those that must be met by an employee to successfully perform
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