Senior Process Engineer
About The Position
Leidos is seeking a hands-on Senior Process Engineer to help develop, implement, and ramp up a new state-of-the-art electronics manufacturing facility. The role supports facility layout development, equipment installation and commissioning, and process optimization across Surface Mount Technology (SMT), conformal coating, inspection, and automated test operations. The engineer collaborates with Manufacturing Engineering, Industrial Engineering, Quality, Facilities, and Operations to establish efficient production workflows, optimize equipment utilization, and support transitions from PCBA manufacturing through subassembly and final integration. The position is part of Leidos Defense Systems Sector / Manufacturing, which provides systems, solutions, and services for defense customers worldwide. The successful candidate will support PCBA assembly and complementary processes, drive process and quality improvements, and help develop the manufacturing engineering team.
Requirements
- Bachelor of Science degree and 12–15 years of prior relevant experience, or a master's degree and 10–12 years of prior relevant experience; alternatively, a high school diploma/GED and 15 years of experience will be considered.
- Must be a U.S. citizen and able to obtain and maintain a final Secret Clearance.
- Previous experience working in PCBA manufacturing and process development.
- Strong background in Design for Manufacturability (DFM) to optimize product designs for production efficiency.
- Must be a resident of Huntsville, Alabama, or willing to relocate to the Huntsville area.
Nice To Haves
- Familiarity with IPC requirements, including J-STD-001 and IPC-A-610.
- Experience with electronics used on launch vehicles, targets, or missile components, such as PCBAs, cable harnesses, or electro-mechanical assemblies.
- Experience with Costpoint Material Planning software and/or Windchill product lifecycle management software.
- Experience working in a mid- to high-volume manufacturing environment.
- Ability to provide Rough Order of Magnitude (ROM) estimates, Basis of Estimate (BOE) documents, and other information to support proposal efforts.
- Demonstrated success implementing lean principles to reduce waste and improve efficiency.
- Experience using Manufacturing Execution Systems (MES), such as Aegis Factory Logix.
- Hands-on experience with PCBA automation equipment, such as SMT mounters, selective solder, board wash, press-fit, AOI, and general soldering equipment.
Responsibilities
- Co-lead and develop the manufacturing engineering team supporting PCBA assembly and complementary processes, including selective solder, press-fit, conformal coating, and board washing.
- Drive continuous improvement projects to increase yield, throughput, and quality across production lines and specialized equipment.
- Monitor manufacturing KPIs, including yield, first-pass yield, cycle time, scrap, and escapes, to identify trends and drive proactive process changes.
- Perform DFM/DFA reviews for new product introductions and design changes, and provide feedback to design engineering.
- Develop, document, and implement manufacturing processes, work instructions, and process control plans.
- Identify, specify, and justify capital equipment for PCBA assembly, conformal coating, and related manufacturing processes.
- Support root cause analysis, corrective action, and disposition of manufacturing and quality nonconformances.
- Partner with quality, production control, and design teams to meet delivery schedules and customer quality requirements.
- Support quality engineering in process development and onsite audits.
- Establish and monitor production-process quality objectives.
- Mentor and develop junior engineers in process development, root cause analysis, and mitigation.
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What This Job Offers
Job Type
Full-time
Career Level
Senior
