Operator NPI and Engineering

Role & responsibilities :

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

Preferred candidate profile

• 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

Education & Experience

• Diploma in Mechanical / Electronics
• 5 - 12 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