The Process Engineer is responsible for developing, industrializing, and continuously improving advanced manufacturing and test processes for high-performance brushless DC motors and voice coil actuators used in aerospace & defense and other mission-critical applications.
This role plays a critical part in new product development (NPD) by designing scalable, automated manufacturing solutions, driving cutting-edge process technologies, and ensuring full compliance with Advanced Product Quality Planning (APQP) requirements.
The Process Engineer partners cross-functionally with Design Engineering, Operations, Quality, and external suppliers to ensure successful product launches, robust process capability, and best-in-class cost, quality, and delivery performance.

General Responsibilities
• Key participant in the development of new production processes and/or adapt existing production processes for assembly, calibration and testing
• Define specifications for production equipment and interact with mechanization (in house) and/or equipment suppliers to ensure equipment will meet specifications
• Key participant in global new product development project teams to enable successful launch of new products
• Collaborate with other departments on process specifications, quality aspects, product specifications and continuity of equipment
• Influence product designs during new product development phase to ensure economical and defect free manufacture
• Developing new or improved manufacturing and testing processes that are necessary to achieve the performance and cost requirements of future device applications
• Organize the arranging of sample lines and process development equipment
• Key participant in advanced quality planning activities
• Coordinates all functional requirements, the reviewing of designs and debugging /qualifying new high volume assembly /test equipment or tooling
• Transferring knowledge to make site personnel
• Support improvement projects to reduce cycle time, defects and manufacturing costs
• Work with suppliers and contract manufacturers to ensure processes are capable, have sufficient controls in place, can meet out delivery requirements, and meet our cost targets
• Evaluate technical capabilities including tooling design, build experience, maintenance program, processes and process controls, cell automation- if required, quality control systems, and material knowledge

Experience / Qualifications

• A university degree required (i.e. Bachelors degree) or equivalent relevant work experience
• Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands
• Strong communication skills; oral, written and presentation
• Strong organization, planning and time management skills to achieve results
• Strong personal and professional ethical values and integrity
• Holds self-accountable to achieving goals and standards
• Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel)
• Strong interpersonal & collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers

• Support the development of advanced manufacturing processes and automation for BLDC Motors and Voice Coil Actuators, including winding, magnet assembly, precision bonding, soldering, laser welding, and actuator assembly.

• Drive innovation in motor manufacturing techniques (e.g., high-speed winding, precision balancing, coil insertion, magnetization, and VCA assembly processes).

• Support execution of APQP deliverables for new product programs, including:

  • Process Flow Diagrams (PFD)

  • PFMEA (Process Failure Mode & Effects Analysis)

  • Control Plans

  • Measurement System Analysis (MSA)

  • PPAP readiness and submission support

• Develop and qualify high-performance test systems for motors and VCAs including:

  • Electrical performance testing (torque, speed, efficiency)

  • Thermal and environmental validation

  • End-of-line functional testing with automated data capture

• Ensure processes meet AS9100 and customer-specific quality requirements.

• Serve as the process engineering lead on cross-functional NPD programs.

• Provide DFM/DFA feedback to design engineering to optimize product manufacturability.

• Drive manufacturing readiness from NBO through SOP and ramp-up, ensuring alignment with cost, quality, and delivery targets.

This position requires eligibility to obtain authorization under the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Non-US Persons, as defined in the ITAR and EAR, may not be eligible to obtain authorization.

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Base Salary Range:

$81,520.00 - $112,090.00

At Sensata, our employees are the key to our success and growth.  We recognize that each individual brings their own unique experience, therefore the base salary range information shown above is a general guideline only.  Sensata considers several factors when extending an offer, including, but not limited to, a candidate9s experience and qualifications, as well as internal equity, market and business considerations. In addition to base salary, Sensata offers competitive medical, dental, vision, life and disability insurance plans, along with education reimbursement, wellness programs, a 401(k) retirement plan with Company matching, and a variety of paid time off, such as vacation or flex-time, sick, bereavement, and parental leave. Certain positions are also eligible for short-term incentive and long-term incentive programs.