Operator - NPI & Engineering

Position: Operator - NPI & Engineering

Organization: Cyient DLM Limited

Location: Shamshabad, Hyderabad

Job Summary

Responsible for leading and supporting box build assembly processes including mechanical assembly, bonding, potting, and conformal coating operations in an EMS environment. The role also involves NPI (New Product Introduction) execution, engineering changes, process optimization, and production readiness for new and existing products.

Key Responsibilities

Box Build & Mechanical Assembly

• Plan, implement, and support complete box build assemblies including:

• PCB integration into enclosures
• Cable harness routing and termination
• Mechanical fitting, fastening, and torque control

• Interpret mechanical drawings, BOMs, and assembly instructions
• Ensure proper alignment, sealing, gasket fitting, and EMI shielding
• Drive improvements in assembly methods, ergonomics, and cycle time

Bonding, Potting & Conformal Coating

• Define and control processes for:

• Bonding (adhesives, sealants, RTV, epoxy)
• Potting & encapsulation (thermal, electrical insulation, vibration protection)
• Conformal coating (acrylic, silicone, urethane, parylene)

• Select materials based on thermal, environmental, and electrical requirements
• Establish process parameters, curing cycles, masking techniques
• Ensure compliance with IPC standards (IPC-A-610, IPC-CC-830, J-STD-001)
• Troubleshoot defects such as:

• Voids, bubbles, delamination
• Coating thickness variation
• Incomplete curing

NPI (New Product Introduction) Engineering

• Lead end-to-end NPI activities from proto to mass production:

• Feasibility analysis
• Process design and validation
• Line setup and pilot builds

• Coordinate with design, quality, supply chain, and customers
• Prepare:

• Work Instructions (WI), SOPs
• PFMEA, Control Plans
• Process flow diagrams

• Conduct trial builds, design validation, and yield improvement

Engineering Modifications / Change Management

• Implement and validate Engineering Change Orders (ECO/ECN)
• Evaluate impact of changes on:

• Process capability
• Production efficiency
• Product reliability

• Update documentation, tooling, and fixtures accordingly
• Support root cause analysis (RCA) and corrective actions (CAPA)

Process Improvement & Quality

• Drive continuous improvement (Kaizen, Lean, Six Sigma principles)
• Improve FPY (First Pass Yield), reduce rework and scrap
• Monitor process KPIs:

• Cycle time
• Yield
• Defect rates

• Work closely with QA for:

• Failure analysis
• Reliability testing
• Audit compliance

Tooling & Equipment Management

• Define and validate fixtures, jigs, and assembly tools
• Support automation opportunities in coating/dispensing processes
• Maintain equipment calibration & preventive maintenance plans

Documentation & Compliance

• Ensure adherence to:

• IPC / ISO standards
• Customer requirements
• ESD and safety guidelines

• Maintain accurate:

• Process documentation
• Build records
• Traceability logs

Requirements

Technical Skills

• Strong knowledge of:

• Box build assembly processes
• Mechanical design integration
• Adhesives, potting compounds, conformal coatings

• Familiarity with:

• IPC standards (A-610, J-STD-001, CC-830)
• CAD drawings interpretation

• Understanding of:

• Thermal management
• EMI/EMC considerations
• Environmental protection methods

Soft Skills

• Problem-solving and analytical thinking
• Cross-functional collaboration
• Strong communication and documentation skills
• Ability to manage multiple NPI projects

Education & Experience

• Diploma in Mechanical / Electronics
• 5–12 years in EMS / electronics manufacturing environment
• Experience in box build and NPI engineering preferred

Preferred Qualifications

• IPC certification (CIT/CIS)
• Six Sigma Green Belt / Lean certification
• Experience with automation in coating/potting dispensing systems
• Exposure to aerospace, automotive, or high-reliability electronics

Key Performance Indicators (KPIs)

• NPI on-time launch success
• First Pass Yield (FPY)
• Reduction in defects (coating/potting failures)
• Engineering change implementation cycle time
• Productivity improvement