Process Engineer

About the Role

• Located in the Exton, PA area.
• Salary range: $80,000 - $100,000 USD.

Key Responsibilities

• Support product development into manufacturing processes through the NPD process by completing tasks such as Design for Manufacturing (DFM), validation protocols, and workflow improvements.
• Ensure key design requirements, tolerances, and manufacturing requirements are identified and met for NPI projects.
• Develop and execute test protocols to validate and verify software/firmware changes affecting products in Production and Service Centers.
• Perform failure investigation on nonconforming material and/or finished products, focusing on mechanical systems and electronic components.
• Analyze customer complaints and Quality reports to implement preventive and corrective actions.
• Utilize manufacturing tests and diagnostic protocols to improve yield, quality, and performance.
• Conduct gauge R&R and other process capability studies to analyze new/existing manufacturing processes.
• Conduct and/or participate in team meetings to improve products and processes.
• Review specifications and confer with R&D, Quality, Manufacturing, and Service personnel to resolve design problems related to material characteristics, dimensional tolerances, service requirements, manufacturing procedures, and costs.
• Act as a liaison between R&D, Production, Service, and Quality, ensuring that changes or new products address Manufacturing, Service, and Quality requirements.
• Coordinate the introduction of product changes or new products by ensuring that procedures and diagnostic protocols are released at the appropriate time, parts are received, and tools are available.
• Review engineering documents, submit revisions, obtain change approvals, and upload documents into the control system.
• Create and maintain process guidelines, routings, and work instructions for assigned projects and product lines.
• Develop preventive maintenance plans for manufacturing equipment and fixtures, calibration procedures, and work instructions for maintaining equipment.
• Work with vendors on corrective actions to solve yield and quality issues.
• Champion continuous improvement and cost reduction activities in manufacturing through Lean/Six-Sigma methodology.
• Demonstrate ability and willingness to use AI tools to improve productivity, decision-making, work quality, and reduce costs. Critically evaluate AI-generated outputs and identify appropriate use cases.

Requirements & Tech Stack

• Bachelor’s degree in Engineering preferred (Mechanical, Industrial, Electrical Engineering Technology, Electronics Engineering).
• Associate of Science (AS) degrees in a related technical area (e.g., electronics test engineer) with relevant experience will also be considered.
• Recent college graduates from related Engineering programs are welcome.
• Design/Repair of assembly and automated test fixtures.
• Knowledge of 5-S, practical problem solving, Root Cause/Corrective Actions, Gauge R&R, and process capability studies.
• Knowledge of Statistical Process Control (SPC) and analytical tools/techniques.
• Knowledge of Six Sigma and Lean Manufacturing methodologies.
• Demonstrated ability and willingness to use AI tools to improve productivity, decision-making, work quality, and reduce costs. The successful candidate must be able to identify appropriate AI use cases and critically evaluate AI-generated outputs.

Qualifications

• Support product development initiatives into manufacturing processes through NPD process by completing various manufacturing related tasks such as, Design for Manufacturing (DFM), validation protocols and workflow improvements.
• Ensure key design requirements, tolerances, and manufacturing requirements are identified and met for NPI projects.
• Develop and execute test protocols to validate and verify software/firmware changes introduced by R&D engineering that affect Faro products in both Production and Service Centers.
• Perform failure investigation on nonconforming material and/or finished products, especially in the areas of mechanical systems and electronic components.
• Analyze customer complaints and Quality reports in order to implement preventive and corrective actions.
• Utilize manufacturing tests, diagnostic protocols, to improve yield, quality, and performance.
• Conducts gauge R&R and other process capability studies to analyze new/existing manufacturing processes.
• Conduct and/or participate in team meetings to improve products and processes.
• Review specifications and confer with R&D, Quality and Manufacturing, and Service personnel to resolve design problems related to material characteristics, dimensional tolerances, service requirements, manufacturing procedures, and costs of tools.
• Act as a liaison between R&D, Production, Service, and Quality ensuring that changes or new products properly address Manufacturing, Service, and Quality requirements.
• Coordinate introduction of product changes or new products by ensuring that procedures and diagnostic protocols are released at the appropriate time, parts have been received, and tools are available.
• Review engineering documents, submit revisions, obtain change approvals and upload documents into control system.
• Create and maintain process guidelines, routings, and work instructions for assigned projects and product lines.
• Develop preventive maintenance plans for manufacturing equipment and fixtures, calibration procedures, and work instructions for maintaining equipment in working order.
• Work with vendors on corrective actions to solve yield and quality issues.
• Champion continuous improvement and cost reduction activities in manufacturing through Lean/Six-Sigma methodology.
• Demonstrated ability and willingness to use AI tools to improve productivity, decision-making, work quality, and to reduce costs.