Summary

We seek a seasoned NPI Process Engineer to drive the seamless transition of complex printed circuit board assemblies (PCBA) from design to volume production. You’ll own NPI readiness for high-mix, low-volume SMT manufacturing, ensuring robust processes, resolving technical roadblocks, and optimizing build efficiency. Your expertise in BOM structures, DFM/DFT, and SMT process excellence will be critical to success.        

Detailed Description

Perform tasks such as, but not limited to, the following:

NPI Process Leadership

• Lead end-to-end NPI preparation for SMT-based PCBA products, including process validation, workflow design, and documentation (PFMEAs, control plans, work instructions).
• Conduct DFM/DFT reviews with design teams to mitigate manufacturing risks and optimize BOM/AVL (Approved Vendor List) alignment.
• Develop SMT process recipes (stencil design, solder paste, reflow profiles) for complex, mixed-technology assemblies.
  
  

BOM & Configuration Management

• Analyze and validate complex multi-level BOMs, ensuring accuracy, alternate component management, and lifecycle compliance.
• Resolve BOM discrepancies, obsolescence issues, and supply chain challenges during NPI phases.
  
  

High-Mix/Low-Volume (HMLV) Optimization

• Design flexible processes for rapid product changeovers and low-volume efficiency.
• Troubleshoot PCBA defects (solder defects, component placement, ICT/FCT failures) using root-cause analysis (8D, Fishbone).
• Implement statistical process control (SPC) for critical-to-quality (CTQ) parameters in SMT lines.
  
  

Cross-Functional Collaboration

• Partner with Design, Test, Supply Chain, and Customer to resolve build issues and ensure on-time delivery.
• Mentor junior engineers and technicians on NPI best practices.

Continuous Improvement

• • Drive yield improvement, cost reduction, and process scalability initiatives.
  • Drive and ensure compliance with quality standards (IPC-A-610, J-STD-001).

Knowledge/Skills/Competencies

Education: BS/MS in Mechanical, Electrical, Industrial Engineering, or related field.
Experience:

• 7+ years in NPI process engineering within  PCBA/SMT manufacturing
• Proven expertise in complex BOM structures (multi-level, configurable, ECO management).
• Hands-on experience with SMT processes(screen printing, SPI, pick-and-place, reflow, AOI, X-ray).
• Track record solving high-mix/low-volume PCBA production challenges.
  
  

Technical Skills:

• DFM/DFT, PFMEA, Process validation
• CAD tools (Valor) and MES.
• Root-cause analysis (8D, 5 Whys), SPC, and Lean methodologies.
• Familiar Standards: IPC-A-610, IPC-J-STD-001, IPC-7711/21.

Preferred Qualifications:

• Experience with flex/rigid-flex PCBA, press-fit connectors, or box-build integration.
• Knowledge of automation solutions for HMLV environments.
• Six Sigma Green/Black Belt certification.
• Familiarity with Industrial product or medical device manufacturing.

Notes

This job description is not intended to be an exhaustive list of all duties and responsibilities of the position. Employees are held accountable for all duties of the job. Job duties and the % of time identified for any function are subject to change at any time.