Senior Manufacturing Engineering Engineer (Sr. NPI Engineer)

PURPOSE OF THIS POSITION:

Be responsible for leading and overseeing the development, optimization, and improvement of complex manufacturing processes within the electronics manufacturing services (EMS) industry. Play a critical role in driving process excellence, innovation, and efficiency to meet customer requirements and organizational goals.

PRIMARY RESPONSIBILITY:

1. New product introduction (NPI):

- Design for Manufacturability (DFM) Review and provide feedback to customer, create process flow diagrams, define critical process parameters, select appropriate equipment, and establish efficient assembly methods. Create and maintain Bills of Materials, build instructions, conducting process trials, and addressing any issues or challenges that arise during the NPI build.

2. Process Development and Optimization:

- Lead the design, development, and optimization of complex manufacturing processes for electronic products, ensuring alignment with customer specifications and industry best practices.

- Conduct advanced feasibility studies, process simulations, and risk assessments to identify opportunities for process improvement, cycle time reduction, and cost optimization.

- Collaborate with cross-functional teams, including design engineers, manufacturing personnel, and suppliers, to implement innovative process solutions and resolve technical challenges.

3. Process Validation and Qualification:

- Develop and execute comprehensive validation plans for new processes, process modifications, and technology transfers.

- Apply advanced statistical techniques to analyze data, evaluate process capabilities, and ensure compliance with quality and regulatory requirements.

- Provide guidance and mentorship to Level 1 and Level 2 engineers in process validation methodologies and best practices.

4. Documentation, Standardization, and Training:

- Develop and maintain comprehensive process documentation, including standard operating procedures (SOPs), work instructions, and process flow diagrams.

- Drive process standardization initiatives across multiple sites, product lines, and customer projects.

- Provide training and mentorship to Level 1 and Level 2 engineers and production personnel on advanced process techniques, methodologies, and quality standards.

5. Component evulation:

- Participate in evaluating the raw material and new supplier/ vendor with SQE, review and propose to customer for alternative component.

6. Equipment and Technology:

- Evaluate and select cutting-edge equipment, tools, and technologies to support manufacturing processes, considering factors such as performance, scalability, and industry trends.

- Collaborate with equipment vendors and suppliers to assess capabilities, conduct trials, and recommend strategic investments in new equipment or process improvements.

- Lead the implementation, commissioning, and qualification of new equipment and technologies, ensuring seamless integration into existing processes.

7. Data Analysis and Performance Monitoring:

- Analyze complex process data using statistical methods, advanced analytics tools, and software to monitor process performance, detect trends, and drive data-driven decision-making.

- Develop real-time process monitoring systems and implement statistical process control (SPC) methodologies to ensure process stability and capability.

- Generate comprehensive reports and present findings to stakeholders and senior management.

8. Troubleshooting and Problem Solving:

- Investigate and resolve issues related to manufacturing processes, equipment failures, and product quality deviations. Work closely with production and maintenance teams to identify root causes, implement corrective actions, and prevent future occurrences.

9. Continuous Improvement and Innovation:

- Drive continuous improvement initiatives to enhance process efficiency, reduce waste, and improve product quality.

- Utilize advanced Lean Six Sigma methodologies, such as DMAIC and DMADV, to identify and eliminate process bottlenecks, reduce variability, and optimize process performance.

- Foster a culture of innovation by researching and evaluating emerging technologies, materials, and processes to drive competitive advantage.

10. Collaboration and Communication:

- Collaborate with cross-functional teams, including engineers, operators, technicians, and management, to ensure effective communication and alignment on process improvement initiatives. Share findings, recommendations, and progress updates with relevant stakeholders.

11. Support Supervisor/ Manager to train for new staff and perform other related duties as designed by superior.

REQUIREMENTS:

- Education: Bachelor's degree in engineering or a related field. A master's degree is preferred

- Experience: At least 5+ years of experience in process engineering within the electronics manufacturing services (EMS) industry, PCBA engineering experience, or box-build parts assembly such as metal parts, plastic parts, and cables

Others:

- Proven track record of successfully leading and implementing process improvement projects.

- Advanced knowledge of manufacturing processes for electronic products, including surface mount technology (SMT), assembly techniques, and testing procedures.

- Proficiency in advanced statistical analysis tools and software for data analysis and process optimization.

- In-depth understanding of quality management systems (e.g., ISO 9001) and regulatory requirements (e.g., RoHS).

- Advanced knowledge of process development and optimization methodologies, such as Design of Experiments (DOE), Statistical Process Control (SPC), Failure Mode and Effects Analysis (FMEA), and decision-making skills.

- Excellent communication and collaboration abilities, including the ability to lead and influence cross-functional teams.

- Project management experience, including planning, execution, and monitoring of complex projects.

- Continuous improvement mindset and a commitment to staying at the forefront of process engineering.

- Willingness to learn new technologies, processes, and tools to drive innovation and process excellence.

- Poka-Yoke and Vavual Stream Mapping mindset and concept.