Senior SMT PCBA Manufacturing / Process Engineer
Jabil
Senior SMT PCBA Manufacturing / Process Engineer
- The Senior SMT PCBA Manufacturing / Process Engineer is responsible for developing, optimizing, and sustaining Surface Mount Technology (SMT) and Printed Circuit Board Assembly (PCBA) manufacturing processes to achieve world-class performance in quality, cost, delivery, and productivity. The role provides technical leadership for NPI, process validation, yield improvement, equipment qualification, automation initiatives, and continuous improvement projects while supporting high-volume production and customer requirements.
Key Responsibilities
1. Process Engineering & Manufacturing Support
▪ Own SMT and PCBA manufacturing processes from stencil printing through reflow, AOI, SPI, selective soldering, wave soldering, depanelization, coating, and final assembly.
▪ Develop and maintain process flows, control plans, PFMEA, work instructions, and process specifications.
▪ Lead process troubleshooting and root cause investigations for manufacturing issues.
▪ Drive yield, throughput, and cycle-time improvement initiatives.
▪ Establish process controls to ensure stable and repeatable production performance.
▪ Monitor process capability (Cp/Cpk) and implement corrective actions when required.
2. New Product Introduction (NPI)
▪ Lead DFM and DFA reviews during product development.
▪ Support manufacturing readiness activities for new product introduction.
▪ Define manufacturing process requirements, tooling, fixtures, and equipment.
▪ Lead pilot builds, engineering builds, and production ramp-up activities.
▪ Develop manufacturing documentation and train production personnel.
▪ Manage product transfer activities between sites or customers.
3. SMT Process Optimization
▪ Optimize the following process areas: solder paste printing, placement processes, reflow profiles, AOI inspection programs, SPI inspection strategies, selective soldering parameters, and wave soldering parameters.
▪ Establish process windows and operating limits.
▪ Improve first-pass yield and reduce defect opportunities.
▪ Analyze defect trends and implement sustainable corrective actions.
4. Equipment & Automation
▪ Lead equipment selection, qualification, installation, and commissioning.
▪ Support SMT printers, pick-and-place machines, reflow ovens, SPI systems, AOI systems, X-Ray systems, and selective soldering equipment.
▪ Develop and implement automation solutions to improve productivity.
▪ Support Industry 4.0 manufacturing initiatives and digitalization programs.
5. Quality & Validation
▪ Lead IQ, OQ, PQ, Process Validation, and Test Method Validation activities.
▪ Perform Gauge R&R, MSA, SPC, and process capability studies.
▪ Review and update PFMEA, Control Plans, and Risk Assessments.
▪ Support customer, ISO, and regulatory audits.
▪ Ensure compliance with IPC standards and customer requirements.
6. Continuous Improvement
▪ Lead Lean Manufacturing initiatives.
▪ Facilitate DMAIC projects, Kaizen events, Value Stream Mapping, and OEE improvement projects.
▪ Drive cost reduction through yield improvement, labor optimization, material savings, automation, and cycle-time reduction.
▪ Establish KPI dashboards and performance monitoring systems.
7. Technical Leadership
▪ Mentor Process Engineers and Manufacturing Engineers.
▪ Provide technical coaching to technicians and production teams.
▪ Lead cross-functional problem-solving activities.
▪ Interface directly with customers regarding technical challenges and improvement initiatives.
▪ Lead engineering reviews and manufacturing readiness assessments.
Technical Requirements
SMT & PCBA Expertise
Strong technical knowledge of:
▪ SMT process development
▪ Stencil design and solder paste technology
▪ Pick-and-place programming
▪ Reflow profiling and optimization
▪ AOI and SPI systems
▪ X-Ray inspection techniques
▪ Wave soldering
▪ Selective soldering
▪ PCB defect analysis
▪ Conformal coating processes
▪ PCBA assembly technologies
Engineering Tools
Proficiency in:
▪ SPC and Minitab
▪ DMAIC and Lean Six Sigma
▪ PFMEA, Process Flow Diagrams, and Control Plans
▪ 8D Methodology, Fishbone Analysis, and 5 Why Analysis
▪ Time Study and Capacity Analysis
▪ AutoCAD (preferred)
▪ MES and manufacturing systems
Quality & Compliance
Strong understanding of:
▪ IPC-A-610
▪ IPC J-STD-001
▪ IPC-7711/7721
▪ ISO 9001
▪ ISO 13485 (preferred)
▪ FDA 21 CFR Part 820 (preferred)
▪ ESD control programs
▪ Change control systems
▪ CAPA processes
Education & Experience
Education
▪ Bachelor's Degree in Electronics, Electrical, Manufacturing, Mechanical, Industrial Engineering, or a related engineering discipline.
Minimum Experience
▪ 8+ years of SMT/PCBA manufacturing engineering experience.
▪ Minimum 5 years supporting high-volume SMT production.
▪ Experience with NPI, process validation, and yield improvement.
Preferred Experience
▪ 10+ years in electronics manufacturing services (EMS).
▪ Experience in a major EMS or equivalent high-mix electronics manufacturing environment.
▪ Lean Six Sigma Green Belt or Black Belt certification.
▪ Experience leading manufacturing transfer projects and multi-site deployments.
Key Performance Indicators
▪ First Pass Yield (FPY)
▪ Defect Rate (DPMO/PPM)
▪ OEE Improvement
▪ SMT Placement Efficiency
▪ Reflow Yield
▪ Cost Reduction Achievement
▪ Cycle Time Reduction
▪ NPI Ramp Success
▪ Corrective Action Closure
▪ Customer Quality Performance
▪ Equipment Utilization