Process Engineer
Tata Electronics
Technology & Process Setup
- Define and maintain all process windows, control plans & CTQ across all products of PnP.
- Setup, Operate, Programming & Optimizing PnP machines.
- Conduct DOE & Process validation for new products and materials.
- Perform feeder loading , nozzle selection & calibration.
- Optimize component placement accuracy and speed.
- Create & modify machine programs using online/offline SW.
- Optimize cycle time and improve placement efficiency.
- Perform Penalization and coordinate transformation.
- Validate BOM , Centroid file and Gerber data before production.
- Develop & Maintain Process documentation, WIs & SOPs (Pick n Place / Mounter)
- All new models trail pre-readiness (EVT/ DVT / PVT) , new model trail activities including trial builds & process validation.
- Load & verify machine programs for New Product Trail.
- Conduct First Article Inspection.
- Partner with NPI, TDG to ensure DFMEA and PFMEA of Pink n Place / Mounter.
- Ensure proper solder paste reflow per component and PCB design requirements
- Ensure smooth technology transfer from development to production.
- Own ramp-up metrics: yield learning curve, cycle time, scrap reduction.
- Accountable for first pass yield, final yield and field reliability.
- Lead root cause analysis for yield excursions using SPI data , SPC charts , Yield Trends ,FMEA, DOE and failure analysis.
- Monitor production yield , defect rates , cycle time and implement corrective / preventive actions.
- Collaborate with Quality , NPI & Customer to resolve manufacturing & Quality issues such as tombstoning , voiding , bridging , cold joints, misalignment , missing components and solder balls.
- Partner with Quality team to address customer returns, audits and escalations.
- Analyze following defects ( Identify root causes of defects like tombstoning , misalignment , missing components etc. ) and implement corrective actions
- Monitor Placement Quality and defect rates.
- Maintain Process documentation & Production reports.
- Own cost of ownership and productivity improvement initiatives.
- Drive Cycle time and line balancing improvements.
- Lead process development , validation & continuous improvement initiatives ( Kaizen , Poka yoke , Lean Manufacturing )
- To ensure Proper line setup , programming , Program version management ( Pick n Place/Mounter )
- To ensure compliance with ESD , Safety& IPC standards.
- Meet daily production targets & OEE goals
- Coordinate with production planning , quality & maintenance teams
- Diagnose and resolve machine alarms and placement defects
- Handle feeder related issues , vision alignment errors & nozzle problems
- Minimize downtime & improve machine utilization
- Serve as a technical team member for customers on PCBA Process Topics.
- Will be technical team member for customer reviews, technology discussions and risk mitigation plans.
- Bachelor in related Engineering Discipline (Preferred Electronics Engineering)
- 10-12 years’ hands on experience in SMT industry in a similar role ( PnP Programming & Optimization )
- Experience in high volume manufacturing environment.
- Hands on knowledge of PnP machines ( ASMPT / Fuji / Panasonic )
- Deep Understanding of solder paste behavior & thermal profiling
- Proficiency in root cause analysis & problem solving tools ( 8D , 5 why , DOE )
- Familiar with Lean manufacturing
- Strong knowledge of SMT Process Flow