Process Engineer

Process Engineer

The Process Engineer is responsible for developing, industrializing, and continuously improving advanced manufacturing and test processes for high-performance brushless DC motors and voice coil actuators used in aerospace & defense and other mission-critical applications. This role plays a critical part in new product development (NPD) by designing scalable, automated manufacturing solutions, driving cutting-edge process technologies, and ensuring full compliance with Advanced Product Quality Planning (APQP) requirements.

The Process Engineer partners cross-functionally with Design Engineering, Operations, Quality, and external suppliers to ensure successful product launches, robust process capability, and best-in-class cost, quality, and delivery performance.

General Responsibilities

• Key participant in the development of new production processes and/or adapt existing production processes for assembly, calibration and testing
• Define specifications for production equipment and interact with mechanization (in house) and/or equipment suppliers to ensure equipment will meet specifications
• Key participant in global new product development project teams to enable successful launch of new products
• Collaborate with other departments on process specifications, quality aspects, product specifications and continuity of equipment
• Influence product designs during new product development phase to ensure economical and defect free manufacture
• Developing new or improved manufacturing and testing processes that are necessary to achieve the performance and cost requirements of future device applications
• Organize the arranging of sample lines and process development equipment
• Key participant in advanced quality planning activities
• Coordinates all functional requirements, the reviewing of designs and debugging/qualifying new high volume assembly/test equipment or tooling
• Transferring knowledge to make site personnel
• Support improvement projects to reduce cycle time, defects and manufacturing costs
• Work with suppliers and contract manufacturers to ensure processes are capable, have sufficient controls in place, can meet out delivery requirements, and meet our cost targets
• Evaluate technical capabilities including tooling design, build experience, maintenance program, processes and process controls, cell automation- if required, quality control systems, and material knowledge

Experience / Qualifications

• A university degree required (i.e. Bachelors degree) or equivalent relevant work experience
• Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands
• Strong communication skills; oral, written and presentation
• Strong organization, planning and time management skills to achieve results
• Strong personal and professional ethical values and integrity
• Holds self-accountable to achieving goals and standards
• Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel)
• Strong interpersonal & collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers

• Support the development of advanced manufacturing processes and automation for BLDC Motors and Voice Coil Actuators, including winding, magnet assembly, precision bonding, soldering, laser welding, and actuator assembly.
• Drive innovation in motor manufacturing techniques (e.g., high-speed winding, precision balancing, coil insertion, magnetization, and VCA assembly processes).
• Support execution of APQP deliverables for new product programs, including:
• Process Flow Diagrams (PFD)
• PFMEA (Process Failure Mode & Effects Analysis)
• Control Plans
• Measurement System Analysis (MSA)
• PPAP readiness and submission support
• Develop and qualify high-performance test systems for motors and VCAs including:
• Electrical performance testing (torque, speed, efficiency)
• Thermal and environmental validation
• End-of-line functional testing with automated data capture
• Ensure processes meet AS9100 and customer-specific quality requirements.
• Serve as the process engineering lead on cross-functional NPD programs.
• Provide DFM/DFA feedback to design…