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. Youll 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.
Key Responsibilities
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).
Required Qualifications
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.
