Sr. Engineer - Process Engineering

Job Title: Process Engineer – Electronics Manufacturing Location: Hyderabad Experience: 2–5 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./B.Tech/Diploma in: Electronics & Communication Engineering Electrical & Electronics Engineering Manufacturing Engineering Mechanical Engineering (with Electronics Manufacturing experience) Experience 2–5 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