Senior NPI Process Manufacturing Engineer

Viavi Solutions Canada ULC; Ottawa; On-site; CAD 71,000 - 133,000; Full time

Benefits offered by this job

Paid time off

Health insurance

Disability insurance

401(k)

Job summary

VIAVI Solutions Canada ULC in Ottawa is seeking a Senior NPI Process Manufacturing Engineer to design and deploy volume manufacturing processes for PLT optical instruments. You will own manufacturing processes from DFM review through pilot builds and into production, coordinating with R&D, Design Eng, and suppliers to ensure readiness and quality.

The role requires hands-on engineering, fixture/tool development, and travel to contract manufacturers.

Qualifications

• Bachelor’s degree in Mechanical, Electrical, Industrial or related engineering field; Master’s preferred.
• 5+ years in manufacturing engineering, with at least 3 years supporting NPIs.
• Lean manufacturing and Six Sigma knowledge; Belt certification a plus.
• Strong SPC and data analysis skills; familiar with JMP/Minitab.
• Experience with CAD for fixture design (SolidWorks/AutoCAD).
• Proven cross-functional collaboration and project leadership.
• Excellent problem-solving and communication skills; travel as needed.

Responsibilities

• Lead development and documentation of manufacturing processes for NPIs to mass production.
• Collaborate with R&D, Design Eng, Supply Chain and Quality on manufacturability and DFA/DFM.
• Design and validate fixtures, tools, and equipment.
• Conduct process capability studies and ensure process stability and control.
• Develop and maintain manufacturing process docs and training material.
• Drive continuous improvement to reduce cost and improve yield.
• Support production readiness at Ottawa facility and contract sites.

Skills

NPI experience

Process development

Lean manufacturing

Six Sigma

SPC/Data analysis

CAD (SolidWorks/AutoCAD)

Cross-functional leadership

Analytical communication

Education

Bachelor’s degree in Engineering

Master’s degree preferred

Tools

JMP

Minitab

Job description

Summary

VIAVI (NASDAQ: VIAV) is a global provider of network test, monitoring and assurance solutions for telecommunications, cloud, enterprises, first responders, military, aerospace, and railway. VIAVI is also a leader in light management technologies for 3D sensing, anti-counterfeiting, consumer electronics, industrial, automotive, government and aerospace applications. We are the people behind the products that help keep the world connected at home, school, work, at play, and everywhere in between. VIAVI employees are passionate about supporting customer success and we welcome people who bring their best every day to the company – to question, to collaborate and to push for solutions that will delight our customers.

Duties & Responsibilities

VIAVI’s Production & Lab Testing (PLT) division in Ottawa designs and manufactures precision optical test and measurement instruments - modular optical test platforms, application-specific integrated test solutions, optical inspection systems, and a broad ecosystem of plug-in modules - that R&D engineers and production lines worldwide rely on to develop, qualify, and manufacture optical components, passive devices, and high-speed optical interconnects. These are the instruments at the center of one of the fastest-moving markets in the industry, as coherent optics, 400G/800G and beyond, DWDM evolution, and AI data center infrastructure build out simultaneously accelerate demand for both the products and the capabilities they test. We are looking for a Senior NPI Process Manufacturing Engineer to join the PLT Operations Engineering NPI team in Ottawa. This is a hands-on process manufacturing engineering role, co-located with R&D, focused on designing and deploying the production ready manufacturing processes that bring PLT’s optical instruments from concept to volume manufacturing. You will own manufacturing process solutions from DFM review through pilot build validation and continue to support those processes through the product lifecycle - including the growing volume of product variants and re-qualification programs that the pace of technology evolution is generating. Note to Applicants: This is a factory process manufacturing engineering role. It is not a field service, customer-facing applications engineering, or quality audit position. The work is hands-on and you will use your opto-mechanical knowledge to develop assembly processes, tools and work instructions for volume production.

Essential Duties and Responsibilities

• Lead the development, optimization and documentation of manufacturing processes for new product introductions (NPIs) from concept through mass production.
• Collaborate closely with R&D, Design Engineering, Supply Chain, and Quality teams to define manufacturing requirements, identify potential risks, and implement design for manufacturability (DFM) and design for assembly (DFA) principles.
• Participate in product design reviews, providing expert input on manufacturing feasibility and process implications.
• Design, develop, and validate manufacturing fixtures, tools, and equipment, including specifying and procuring new machinery when necessary.
• Conduct process capability studies (CpK, PpK), Gage R&R, and other statistical analyses to ensure process stability and control.
• Develop and implement comprehensive manufacturing process documentation, including work instructions, control plans, and training materials.
• Drive continuous improvement initiatives on NPI processes to enhance efficiency, reduce costs, improve quality, and increase yield.
• Perform root cause analysis and implement corrective actions for manufacturing issues encountered during NPI phases.
• Drive detailed project planning to ensure all manufacturing processes are developed, documented, debugged, deployed, and validated prior to production pilot run.
• Partner with R&D and Test Engineering to develop contract manufacturing-ready tools and jigs and fixtures.
• Process Optimization: Optimize manufacturing processes for cycle time and capacity.
• Install and validate production systems at the Ottawa facility and contract manufacturing sites in Asia.
• Support the PLT TL9000 Periodic Re-test program, ensuring that production procedures are maintained to the standard required.
• Maintain and update existing production processes throughout the product lifecycle.
• Communicate effectively with stakeholders including R&D, PLM, Program Management, Test Engineering, and contract manufacturing partners; collaborate comfortably across time zones with the extended team.
• Actively engage with the team and management by reporting status against commitments and demonstrating self-directed initiative and leadership.

Pre-Requisites / Skills / Experience Requirements

Education Bachelor's degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, or a related technical field. Master's degree preferred.

Experience and Technical Skills

• 5+ Years in manufacturing engineering role, with at least 3 years directly supporting New Product Introduction (NPI).
• Proven experience with process development, characterization, and optimization in volume manufacturing environment, preferably in optics, photonics, electronics, or telecommunications.
• Strong understanding of manufacturing principles, lean manufacturing, Six Sigma methodologies (Green Belt or Black Belt certification a plus).
• Proficiency in statistical process control (SPC) and data analysis tools (e.g., JMP, Minitab).
• Experience with CAD software (e.g., SolidWorks, AutoCAD) for fixture design and review.
• Demonstrated ability to work effectively in cross-functional teams and lead technical projects.
• Excellent problem-solving, analytical, and communication skills (written and verbal).
• Ability to travel occasionally to contract manufacturers or other company sites as needed.
• Understanding of optical measurement principles relevant to PLT products - insertion loss, return loss, optical power measurement, wavelength accuracy, polarization effects, amplifier characteristics, filter passband behavior, and the connector types, cleanliness standards, and end-face geometry that underpin measurement quality.
• Demonstrated leadership and self-motivation; effective cross-functional collaborator who can fully represent test engineering on a multi-site, geographically distributed product development team.

VIAVI Solutions is an equal opportunity and affirmative action employer - minorities/females/veterans/persons with disabilities.

Job Posting Pay Range: 71,400 to 132,600 Exceptional qualifications, experience and location may impact salary.

VIAVI offers a competitive benefits package that includes paid time off, health, life and disability insurance, 401(k), and a bonus program.

VIAVI empowers Service Providers and IT organizations to manage the network lifecycle for complex 5G and Fiber networks with intuitive instruments, systems and technologies; and our expertise in light management and optical coatings help protect the world's bank notes from counterfeiters, enhance the colors you see, and enable advanced technology such as 3D sensing. We are a team of thought leaders who have the freedom to support and innovate and look for new effective and efficient solutions for our customers.