Job Title: Process Engineer Electronics Manufacturing

Location: Hyderabad

Experience: 25 Years

Industry: Electronics Manufacturing Services (EMS) Aerospace Defense Medical Electronics High-Reliability Electronics

Job Summary

We are seeking a highly competent and technically strong Process Engineer with proven expertise in end-to-end electronics manufacturing processes including SMT PTH Box Build Electro-Mechanical Assembly Cable Harness Mechanical Integration and FAIR validation activities.

The ideal candidate will demonstrate strong ownership in process establishment validation troubleshooting yield improvement process control and continuous improvement initiatives. The role requires the ability to independently drive manufacturing excellence in a high-mix low-volume and complex product manufacturing environment.

Key Responsibilities

1. End-to-End Process Engineering Ownership

• Own complete process engineering activities from NPI builds through mass production stabilization.
  
• Define validate optimize and sustain robust manufacturing processes.
  
• Lead process readiness reviews prior to product release into production.
  
• Establish manufacturing process capability aligned with customer requirements and internal quality standards.
  
• Drive process standardization and manufacturing best practices across production lines.
  

2. SMT Process Engineering Excellence

• Develop validate and optimize SMT processes including:
  
  • Solder Paste Printing
    
  • SPI (Solder Paste Inspection)
    
  • Pick & Place Programming
    
  • Reflow Soldering
    
  • AOI (Automated Optical Inspection)
    
  • X-Ray Inspection
    
• Establish process windows and optimize machine parameters.
  
• Perform thermal profiling and solder joint reliability validation.
  
• Analyze solder-related defects and implement permanent corrective actions.
  
• Improve First Pass Yield (FPY) Overall Equipment Effectiveness (OEE) and manufacturing efficiency through process optimization.
  

3. PTH / Wave Solder / Selective Solder Process Engineering

• Develop and control manufacturing processes for:
  
  • Through-Hole Assembly
    
  • Manual Component Insertion
    
  • Wave Soldering
    
  • Selective Soldering
    
  • Hand Soldering Operations
    
• Optimize process parameters including:
  
  • Flux Application
    
  • Preheat Settings
    
  • Conveyor Speed
    
  • Solder Pot Temperature
    
  • Dwell Time
    
• Reduce soldering defects through process characterization and validation.
  
• Ensure compliance with IPC workmanship and soldering standards.
  

4. Box Build & System Integration Engineering

• Define complete assembly methodologies and process flows for box-build and system integration products.
  
• Establish process sequencing takt time requirements tooling strategies and assembly controls.
  
• Drive manufacturing readiness for final assembly and system integration builds.
  
• Ensure compliance with product configuration requirements and customer specifications.
  
• Support functional integration and manufacturing process validation activities.
  

5. Mechanical Process Engineering

Provide technical leadership in:

• Mechanical drawing interpretation
  
• GD&T application and tolerance analysis
  
• Torque control methodologies
  
• Fastening systems and assembly controls
  
• Press-fit operations
  
• Adhesive dispensing processes
  
• Bonding and sealing applications
  
• Gasket installation processes
  
• Fixture validation and qualification
  
• Mechanical tolerance stack-up analysis
  

Drive electro-mechanical assembly optimization with focus on precision repeatability product quality and defect prevention.

6. FAIR Validation & Engineering Documentation

• Lead FAIR (First Article Inspection Report) preparation and validation activities.
  
• Develop and maintain:
  
  • Process Flow Diagrams
    
  • PFMEA
    
  • Control Plans
    
  • SOPs
    
  • Work Instructions
    
  • Validation Reports
    
  • Process Qualification Documents
    
• Manage Engineering Change Notices (ECN) and Engineering Change Orders (ECO).
  
• Ensure compliance with customer documentation requirements and quality standards.
  

7. Root Cause Analysis & Process Improvement

Lead structured problem-solving initiatives using:

• 8D Methodology
  
• 5 Why Analysis
  
• Fishbone (Ishikawa) Analysis
  
• Pareto Analysis
  
• Statistical Process Control (SPC)
  
• Process Capability Analysis
  

Drive measurable improvements in:

• Yield Performance
  
• Defect PPM Reduction
  
• Cycle Time Optimization
  
• Throughput Improvement
  
• Process Stability
  
• Manufacturing Cost Reduction
  

8. NPI & Production Support

• Provide technical leadership during prototype pilot and production ramp-up builds.
  
• Conduct DFM (Design for Manufacturability) and DFA (Design for Assembly) reviews.
  
• Identify manufacturing risks proactively and implement mitigation plans.
  
• Support seamless transfer from engineering builds to production release.
  
• Collaborate closely with Design Quality Production Supply Chain and Customer teams.
  

9. Lean Manufacturing & Operational Excellence

Drive continuous improvement initiatives including:

• Lean Manufacturing
  
• Kaizen Activities
  
• Line Balancing
  
• Capacity Optimization
  
• Waste Elimination
  
• Poka-Yoke Implementation
  
• 5S Deployment
  
• Visual Management Systems
  

Promote a culture of operational excellence and process discipline.

Required Qualifications

Education

• B.E./ in:
  
  • Electronics & Communication Engineering
    
  • Electrical & Electronics Engineering
    
  • Manufacturing Engineering
    
  • Mechanical Engineering (with Electronics Manufacturing experience)
    

Experience

• 25 years of hands-on experience in Electronics Manufacturing Services (EMS).
  
• Experience in high-mix low-volume manufacturing environments preferred.
  

Mandatory Technical Skills

Strong working knowledge and hands-on experience in:

SMT Process Engineering

PTH / Wave Soldering / Selective Soldering

Box Build Assembly

Cable Harness Assembly

Electro-Mechanical Integration

Mechanical Assembly Controls

FAIR Documentation & Validation

Process Qualification & Validation

IPC Standards & Workmanship Requirements

Root Cause Analysis & Troubleshooting

Yield Improvement & Process Optimization

Engineering Documentation & Change Management

Preferred Industry Experience

Experience in one or more of the following industries:

• Aerospace Electronics Manufacturing
  
• Defense Electronics
  
• Medical Electronics
  
• Industrial Automation Electronics
  
• High-Reliability Electronics Manufacturing
  

Exposure to the following standards is highly preferred:

• AS9100
  
• IPC-A-610
  
• IPC J-STD-001
  
• IPC/WHMA-A-620
  
• Customer-Specific Quality Requirements
  

Key Competencies

• Strong Technical Ownership
  
• Multi-Process Manufacturing Expertise
  
• Analytical & Problem-Solving Skills
  
• Data-Driven Decision Making
  
• Cross-Functional Collaboration
  
• Execution Excellence
  
• Process Discipline
  
• Continuous Improvement Mindset
  
• Customer Focus
  
• Leadership & Accountability