Operator NPI & Engineering

Position: Operator - NPI & Engineering

Organization: Cyient DLM Limited

Location: Shamshabad Hyderabad

Job Summary

Responsible for leading and supporting box build assembly processes including mechanical assembly bonding potting and conformal coating operations in an EMS environment. The role also involves NPI (New Product Introduction) execution engineering changes process optimization and production readiness for new and existing products.

Key Responsibilities

1. Box Build & Mechanical Assembly

• Plan implement and support complete box build assemblies including:
  
• PCB integration into enclosures
  
• Cable harness routing and termination
  
• Mechanical fitting fastening and torque control
  
• Interpret mechanical drawings BOMs and assembly instructions
  
• Ensure proper alignment sealing gasket fitting and EMI shielding
  
• Drive improvements in assembly methods ergonomics and cycle time
  

2. Bonding Potting & Conformal Coating

• Define and control processes for:
  
• Bonding (adhesives sealants RTV epoxy)
  
• Potting & encapsulation (thermal electrical insulation vibration protection)
  
• Conformal coating (acrylic silicone urethane parylene)
  
• Select materials based on thermal environmental and electrical requirements
  
• Establish process parameters curing cycles masking techniques
  
• Ensure compliance with IPC standards (IPC-A-610 IPC-CC-830 J-STD-001)
  
• Troubleshoot defects such as:
  
• Voids bubbles delamination
  
• Coating thickness variation
  
• Incomplete curing
  

3. NPI (New Product Introduction) Engineering

• Lead end-to-end NPI activities from proto to mass production:
  
• Feasibility analysis
  
• Process design and validation
  
• Line setup and pilot builds
  
• Coordinate with design quality supply chain and customers
  
• Prepare:
  
• Work Instructions (WI) SOPs
  
• PFMEA Control Plans
  
• Process flow diagrams
  
• Conduct trial builds design validation and yield improvement
  

4. Engineering Modifications / Change Management

• Implement and validate Engineering Change Orders (ECO/ECN)
  
• Evaluate impact of changes on:
  
• Process capability
  
• Production efficiency
  
• Product reliability
  
• Update documentation tooling and fixtures accordingly
  
• Support root cause analysis (RCA) and corrective actions (CAPA)
  

5. Process Improvement & Quality

• Drive continuous improvement (Kaizen Lean Six Sigma principles)
  
• Improve FPY (First Pass Yield) reduce rework and scrap
  
• Monitor process KPIs:
  
• Cycle time
  
• Yield
  
• Defect rates
  
• Work closely with QA for:
  
• Failure analysis
  
• Reliability testing
  
• Audit compliance
  

6. Tooling & Equipment Management

• Define and validate fixtures jigs and assembly tools
  
• Support automation opportunities in coating/dispensing processes
  
• Maintain equipment calibration & preventive maintenance plans
  

7. Documentation & Compliance

• Ensure adherence to:
  
• IPC / ISO standards
  
• Customer requirements
  
• ESD and safety guidelines
  
• Maintain accurate:
  
• Process documentation
  
• Build records
  
• Traceability logs
  

Requirements

Technical Skills

• Strong knowledge of:
  
• Box build assembly processes
  
• Mechanical design integration
  
• Adhesives potting compounds conformal coatings
  
• Familiarity with:
  
• IPC standards (A-610 J-STD-001 CC-830)
  
• CAD drawings interpretation
  
• Understanding of:
  
• Thermal management
  
• EMI/EMC considerations
  
• Environmental protection methods
  

Soft Skills

• Problem-solving and analytical thinking
  
• Cross-functional collaboration
  
• Strong communication and documentation skills
  
• Ability to manage multiple NPI projects
  

Education & Experience

• Diploma in Mechanical / Electronics
  
• 512 years in EMS / electronics manufacturing environment
  
• Experience in box build and NPI engineering preferred
  

Preferred Qualifications

• IPC certification (CIT/CIS)
  
• Six Sigma Green Belt / Lean certification
  
• Experience with automation in coating/potting dispensing systems
  
• Exposure to aerospace automotive or high-reliability electronics
  

Key Performance Indicators (KPIs)

• NPI on-time launch success
  
• First Pass Yield (FPY)
  
• Reduction in defects (coating/potting failures)
  
• Engineering change implementation cycle time
  
• Productivity improvement