AOI Engineer
Listed on 2026-02-06
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Engineering
Manufacturing Engineer, Quality Engineering, Electronics Engineer, Electrical Engineering
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FRONT Solutions, LLC is a full-service Electronics Manufacturing Services (EMS) provider located in Erie, PA. The company specializes in delivering value-added services to customers in high-reliability sectors such as Aerospace, Defense, Industrial Controls, and Transportation. With advanced capabilities in PCB Assembly and Test, Cable Assembly and Test, and System Level Assembly and Test, 4
FRONT Solutions supports critical industries with high-quality, precision-driven solutions.
Our growing, state-of-the-art facility in Deland, FL has an exciting opportunity for a AOI Engineer.
The AOI Engineer is responsible for developing, optimizing, and sustaining Automated Optical Inspection (AOI) programs to ensure consistent product quality, high first-pass yield, and minimal false calls in a high-mix electronics manufacturing environment. This role works closely with Process Engineering, Quality, and Production to identify defects, drive root-cause corrective actions, and continuously improve inspection effectiveness.
Key Responsibilities
- Develop, create, and maintain AOI programs for SMT and PCBA assemblies across multiple product lines
- Optimize AOI performance to balance defect detection, false call reduction, and throughput
- Validate AOI inspection criteria in accordance with IPC standards and customer requirements
- Perform root cause analysis on AOI-detected defects and collaborate with Process Engineering on corrective actions
- Support NPI by programming AOI systems for new products and conducting first article inspections
- Analyze AOI data and trends to identify process issues and improvement opportunities
- Troubleshoot AOI equipment, imaging, lighting, and algorithm settings
- Work with Quality Engineering to support audits, customer complaints, and containment actions
- Train operators and technicians on AOI operation, defect recognition, and escalation procedures
- Ensure AOI programs are documented, revision-controlled, and aligned with change management processes
- Support continuous improvement initiatives to increase yield, reduce escapes, and improve inspection efficiency
Required Qualifications
- Associate’s or Bachelor’s degree in Engineering, Electronics, or equivalent experience
- 3+ years of experience programming and supporting AOI systems in an SMT manufacturing environment
- Strong understanding of SMT processes, solder joint formation, and common assembly defects
- Experience interpreting CAD data, Gerber files, and BOMs for inspection programming
- Working knowledge of IPC-A-610 and IPC-7351 standards
- Strong analytical, troubleshooting, and problem-solving skills
- Ability to work cross-functionally in a fast-paced, high-mix environment
Preferred Qualifications
- Experience with one or more AOI platforms (e.g., Koh Young, Mirtec, Omron, Cyber Optics)
- Experience supporting high-reliability products (medical, aerospace, automotive, defense)
- Familiarity with SPC, PFMEA, and Lean manufacturing principles
- Experience supporting SPI or AXI systems is a plus
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