Process Engineer

Job Overview

We are seeking a seasoned Process Engineer specializing in Pick and Place (PnP) machinery to join our team at Tata Electronics, located in Kolar, Karnataka. The candidate will be responsible for overseeing and enhancing SMT manufacturing processes with a focus on programming, optimization, and quality assurance for PnP equipment.

Technology and Process Setup

• Define, control, and maintain all process parameters, control plans, and critical-to-quality (CTQ) metrics across all PnP products.
• Operate, program, and optimize PnP machines including feeder loading, nozzle selection, calibration, and placement accuracy improvement.
• Perform Design of Experiments (DOE) and validate processes for new products and materials.
• Create and update machine programs both online and offline.
• Enhance cycle time efficiency and placement performance through penalization and coordinate transformation techniques.
• Validate Bills of Materials (BOM), centroid files, and Gerber data prior to production phases.

New Model Readiness

• Develop and maintain detailed process documentation, work instructions, and standard operating procedures for PnP and mounter operations.
• Manage pre-readiness trail activities for new models, including EVT, DVT, and PVT phases.
• Load and verify machine programs for new product trials; conduct First Article Inspections.
• Collaborate with NPI and TDG teams to ensure comprehensive DFMEA and PFMEA for PnP and mounter processes.
• Ensure proper solder paste reflow aligned with component and PCB design requirements; facilitate seamless technology transfer from development to production.
• Track and own ramp-up metrics such as yield curves, cycle times, and scrap reduction.

Quality Excellence

• Be accountable for first pass yield, final yield, and field reliability metrics.
• Lead root cause analyses for yield deviations utilizing SPI data, SPC charts, yield trends, FMEA, DOE, and failure investigations.
• Monitor production yield, defect rates, and cycle times; implement corrective and preventive measures.
• Work closely with Quality, NPI, and customers to resolve manufacturing and quality concerns like tombstoning, voiding, bridging, cold joints, misalignment, missing components, and solder balls.
• Partner with Quality teams on customer returns, audits, and issue escalations.
• Maintain precise process documentation and production reports; continuously monitor placement quality and defect trends.

Operational Excellence and Cost Optimization

• Take ownership of cost of ownership and lead productivity enhancement projects.
• Drive cycle time reductions and line balancing improvements.
• Lead continuous improvement initiatives including Kaizen, Poka-Yoke, and Lean Manufacturing methods.
• Ensure proper line setup, programming, and version control for PnP and mounter equipment.
• Enforce compliance with ESD, safety, and IPC standards.
• Meet daily production targets and Overall Equipment Effectiveness (OEE) goals.
• Collaborate with production planning, quality, and maintenance teams to troubleshoot machine alarms, placement defects, feeder issues, vision alignment errors, and nozzle problems.
• Minimize equipment downtime and maximize utilization.

Customer and Stakeholder Engagement

• Act as a technical representative in customer discussions focused on PCBA process topics.
• Participate actively in customer reviews, technology dialogues, and risk mitigation planning.

Educational and Experience Requirements

• Bachelor's degree in a related engineering discipline, preferably Electronics Engineering.
• A minimum of 10-12 years of practical experience in the SMT industry in roles involving PnP programming and optimization.

Desired Skills and Experience

• Experience operating in high-volume manufacturing environments.
• Hands-on expertise with PnP machines such as ASMPT, Fuji, and Panasonic.
• In-depth understanding of solder paste properties and thermal profiling techniques.
• Advanced skills in root cause analysis and problem-solving tools including 8D, 5 Whys, and DOE.
• Familiarity with Lean Manufacturing principles.
• Strong knowledge of the SMT process flow.