Engineer - NPI & Engineering

Position Summary

We are looking for a highly motivated and technically competent NPI Engineer with proven experience in EMS manufacturing. The ideal candidate should possess in-depth knowledge of SMT, THT, Selective Soldering, Box Build Assembly, and Test Processes, along with expertise in driving New Product Introduction from RFQ stage to successful mass production.

The candidate should be capable of independently managing customer projects, leading cross-functional teams, driving manufacturing excellence initiatives, improving process capability, and achieving business KPIs through Kaizen, Lean Manufacturing, and Continuous Improvement methodologies.

Requirements

Key Responsibilities

New Product Introduction (NPI)

• Lead complete NPI lifecycle from customer onboarding to volume production.

• Review and analyse customer packages including:

  • BOM
  • Gerber Files
  • Assembly Drawings
  • Test Specifications
  • AVL
  • Customer Quality Requirements

• Coordinate with Program Management, Quality, Production, Engineering, SCM, and Customers for project execution.

• Conduct Manufacturing Readiness Reviews (MRR) before production launch.

• Manage prototype, EVT, DVT, PVT, Pilot Build, and Ramp-up activities.

• Drive Build Reviews and Lessons Learned documentation.

• Ensure smooth product transfer from NPI to Operations without quality or delivery impact.

EMS Manufacturing Process Expertise

Strong practical understanding and process ownership of:

SMT Process

• Stencil Design Validation
• Solder Paste Selection
• Screen Printing Optimization
• SPI Process Control
• Pick & Place Programming
• Reflow Profile Development
• AOI Programming & Optimization
• SMT Yield Improvement

THT / PTH Process

• Wave Soldering
• Selective Soldering
• Manual Assembly Processes
• Solderability Assessment
• Defect Reduction Activities

Box Build Assembly

• Electro-Mechanical Integration
• Wiring Harness Assembly
• System Integration
• Functional Verification
• Final Packing Requirements

Testing Processes awareness

• ICT
• FCT
• Boundary Scan
• Burn-In Testing
• Environmental Testing
• Customer Specific Test Requirements

Manufacturing Engineering & Process Development

• Lead DFM, DFA, DFT, and DFC reviews.

• Develop optimized manufacturing processes for new products.

• Prepare and maintain:

  • Process Flow Charts
  • Control Plans
  • SOPs
  • Work Instructions
  • PFMEA
  • Risk Assessment Documents

• Define tooling, fixtures, jigs, and test equipment requirements.

• Validate production line capability before mass production.

• Drive First Pass Yield (FPY) improvement initiatives.

Continuous Improvement & Kaizen

• Lead Kaizen projects across manufacturing operations.

• Drive Lean Manufacturing implementation.

• Conduct Value Stream Mapping (VSM) exercises.

• Implement:

  • 5S
  • Poka-Yoke
  • Visual Management
  • Standard Work Practices

• Identify opportunities for:

  • Cycle Time Reduction
  • Cost Reduction
  • Yield Improvement
  • Productivity Enhancement
  • Material Usage Optimization

• Drive automation opportunities wherever feasible.

• First Pass Yield (FPY)

• Rolled Throughput Yield (RTY)

• OEE (Overall Equipment Effectiveness)

• Productivity

• Capacity Utilization

• Defects Per Million (DPMO)

• RMA Reduction

• Customer Complaints

• On-Time Delivery (OTD)

• Cost of Poor Quality (COPQ)

• Scrap Reduction

• Rework Reduction

• Engineering Change Closure Time

Drive corrective actions to ensure targets are consistently achieved.

Problem Solving & Quality Improvement

• Lead root cause analysis activities using:

  • 8D
  • 5 Why Analysis
  • Fish bone Diagram
  • Pareto Analysis
  • CAPA Methodology

• Resolve manufacturing and customer issues through systematic investigations.

• Participate in customer audits and quality reviews.

• Drive process capability improvements using SPC and statistical analysis tools.