Sr Process Engineer

Job Description

As a Senior Process Engineer – Electronics Assembly at Honeywell Aerospace, you will develop, optimize, and sustain manufacturing processes for electronic assemblies, including microelectronic assembly (RF and waveguide), mechanical integration, and final system build. You will drive process capability, quality performance, cost reductions, and operational efficiency through data‑driven problem solving, cross‑functional collaboration, and technical leadership.

You will report directly to the Senior Manufacturing Engineering Supervisor and work out of our Woburn, MA location on an on‑site schedule.

In this role, you will impact the efficiency and quality of our electronics manufacturing operations, ensuring high standards in process development and continuous improvement that support product excellence and customer satisfaction.

• Lead development, qualification, and continuous improvement of electronics assembly processes (SMT, wave/selective solder, manual assembly, microwave hybrid assembly, conformal coating, testing, wire bonding, etc.).
• Define and maintain process parameters, work instructions, PFMEAs, control plans, and standard operating procedures.
• Specify, evaluate, and implement new production equipment, tooling, and automation to improve throughput, quality, and ergonomics.
• Drive root‑cause investigations using structured problem‑solving methodologies (8D, DMAIC, PFMEA updates).
• Using Lean and Six Sigma, analyze production data to identify trends, process variation, and areas for improvement.
• Support NPI (New Product Introduction) activities, including DFM/A reviews, process design, and production readiness.
• Partner with Quality Engineering to resolve defects, reduce scrap/rework, and strengthen process controls.
• Train operators and technicians on new processes, equipment, and best practices.
• Lead or contribute to cost reduction initiatives related to materials, processes, and yields.
• Ensure compliance with applicable standards (IPC A‑610, J‑STD‑001, ISO 9001, AS9100, etc.).
• Act as the technical subject matter expert for electronics assembly processes.

• Medical, Vision, Dental, Mental Health coverage
• Paid vacation
• 401(k) plan / retirement benefits (as per regional policy)
• Career growth opportunities
• Professional development support

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, Industrial Engineering, or related field.
• 7+ years of experience in electronics manufacturing, microelectronics assembly, or related process engineering role.
• Strong knowledge of microelectronic assembly, soldering standards, IPC guidelines, and PCB manufacturing fundamentals.
• Hands‑on experience with equipment such as pick‑and‑place machines, reflow ovens, AOI/AXI, wave/selective solder, automatic bonding, and conformal coating.
• Demonstrated proficiency in process characterization, DOE, SPC, and data analysis.
• Proven experience leading cross‑functional projects from concept to implementation.

• Experience in aerospace, defense, or highly regulated manufacturing environments.
• Six Sigma Green or Black Belt certification.
• Experience with automation systems, robotics, or advanced manufacturing technologies.
• Knowledge of ERP/MRP systems (SAP, Oracle, etc.).
• Prior experience mentoring engineers or leading technical teams.