Senior Manufacturing Engineer

Viavi Solutions • Indianapolis, IN

7d • Onsite

About The Position

VIAVI Solutions is seeking a Senior Manufacturing Engineer to join the founding members of a new Operations Engineering NPI team in Indianapolis. This role is chartered with bringing VIAVI's next generation of fiber optic test instruments from R&D into volume manufacturing. The Senior Manufacturing Engineer will own the process flow, tooling, fixturing, work instructions, and qualification processes for these new products. This is a factory process and industrialization role, not a product design, field service, or production supervision position. The role offers opportunities for professional growth, including structured training in photonics processes, greenfield ownership of process definition, and global exposure through collaboration with international R&D and contract manufacturing partners.

Requirements

• Bachelor of Science in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Electrical Engineering, or a related technical field.
• 5+ Years in Manufacturing or NPI Engineering: Developing and qualifying assembly processes for electronic, electromechanical, or electro-optical products.
• Demonstrated command of DFM/DFA, PFMEA, control plans, first article inspection, process capability analysis, and build readiness reviews.
• Proven ability to author clear, unambiguous work instructions and process specifications that a production operator can actually follow.
• Experience specifying and qualifying assembly tooling and fixtures; familiarity with 3D CAD (SolidWorks, Creo, or equivalent).
• Hands-on experience with high-precision, low-tolerance assembly involving delicate components and contamination-sensitive processes.
• Practical application of SPC, Cpk, and root cause problem-solving methodologies (8D, fishbone, 5-Why).
• Demonstrated leadership and self-motivation; effective cross-functional collaborator who can fully represent manufacturing engineering on a distributed, multi-site product development team.
• Willingness to travel domestically and internationally (approximately 15–25%), including to St. Etienne, France and contract manufacturing sites.

Nice To Haves

• Direct experience with fiber handling, fusion splicing, connectorization, or optical assembly processes.
• Familiarity with industry standard end-face pass/fail criteria.
• Familiarity with Class 1M/3B laser safety practices in a manufacturing environment.
• Experience preparing transfer packages and supporting CM launches, particularly in Asia or Europe.
• Experience with ruggedized handheld instruments — enclosure assembly, overmold, battery integration, IP sealing, and drop/environmental qualification.
• Experience with modular or configurable product platforms where a common mainframe accepts multiple module configurations.
• ERP/PLM system proficiency (SAP, Oracle, Windchill, Agile, or equivalent) for BOM, routing, and change management.
• Six Sigma Green/Black Belt, Lean certification, or equivalent continuous improvement credentials.
• Use of AI tools for process analysis, documentation development, or manufacturing data analysis.

Responsibilities

• Define the build process: Own end-to-end manufacturing process design for new fiber optic instruments — process flow, assembly sequence, station definition, routings, and work content — from PCBA integration through optical subassembly, final assembly, calibration, and pack-out.
• Develop and qualify optical assembly processes for fiber handling and routing, bend radius control, splicing and connectorization, optical connector integration (SC/LC/FC, UPC/APC), adhesive dispense and cure, and optical subassembly alignment.
• Establish connector end-face inspection and cleaning protocols to industry standards and the broader cleanliness discipline that fiber optic assembly yield depends on.
• Define line layout, station ergonomics, cycle time, line balance, and labor content; model capacity against forecast volumes and identify constraints.
• Partner with R&D to provide structured DFM/DFA feedback on part design, tolerance stack-up, fastening and joining methods, optical accessibility, and assembly sequence.
• Participate in design reviews as the manufacturing voice; quantify the cost and yield impact of design choices.
• Drive design changes that reduce part count, assembly time, scrap risk, and the need for skilled manual operations.
• Specify, design, procure, and qualify assembly tooling, fixtures, jigs, and process equipment, working with internal resources and external suppliers.
• Partner with the Senior Test Engineer to ensure assembly fixturing and test fixturing interfaces are compatible and CM-ready.
• Develop and execute equipment qualification and process validation protocols; own the data that proves a process is capable before release.
• Build capital justifications for tooling and equipment in support of the Operations Engineering Manager's capital plan.
• Author and maintain manufacturing documentation: work instructions, visual aids, process specifications, assembly drawings, routings, and inspection criteria.
• Lead PFMEA development and translate the output into control plans with defined process controls, reaction plans, and inspection points.
• Apply statistical methods — SPC, process capability (Cpk), and designed experiments — to characterize and control critical processes.
• Manage engineering change orders (ECOs) affecting manufacturing, including BOM structure, routing, and documentation impact.
• Plan and lead prototype, pilot, and first-article builds; capture issues, drive them to root cause, and close them before production release.
• Prepare the complete manufacturing transfer package and lead the transfer of new products to internal VIAVI factories and contract manufacturing partners.
• Train factory and CM engineering and production staff on new processes; validate that the receiving site can execute the process as designed.
• Support production ramp on site, resolving process issues in real time and confirming yield and cycle time targets are met.
• Monitor yield, scrap, rework, and cycle time across the portfolio; lead root cause investigation and permanent corrective action for manufacturing escapes.
• Drive cost reduction and productivity improvement using Lean and Six Sigma methods.
• Maintain process documentation and tooling throughout the product lifecycle, including support for component obsolescence and second-source qualification.
• Communicate effectively with R&D, Product Line Management, Quality, Supply Chain, and contract manufacturing partners, including across time zones.
• As a founding member of a new team, help establish team norms and practices in addition to individual technical delivery.
• Report status against commitments, demonstrate self-directed initiative, and mentor less experienced engineers and technicians as the team grows.

Benefits

• Photonics Process Training: Structured ramp-up on fiber handling, splicing, connectorization, and optical cleanliness control if you are coming from an adjacent electromechanical or electro-optical background.
• Greenfield Ownership: Define the process architecture, documentation standards, and tooling strategy for a portfolio, rather than inheriting someone else's.
• Global Exposure: Direct working relationships with an international R&D organization and with contract manufacturing partners.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior