Process Development Engineer

Flintex Consulting; Johor Bahru; On-site; MYR 120,000 - 190,000; Full time

Job summary

Flintex Consulting Pte Ltd is seeking an experienced NPI Project Manager to lead new product introductions from concept through mass production. You will plan processes, coordinate cross-functional teams, and drive manufacturing improvements for connector products and automated inspection systems.

The role emphasizes DFM reviews, equipment qualification, and successful transfer to mass production, working with local and overseas suppliers to meet production targets and quality standards.

Qualifications

• Bachelors or diploma in a related engineering field.
• Minimum 5 years of NPI, process development or manufacturing engineering experience.
• Experience in developing semi- or fully automated assembly lines and inspection systems.

Responsibilities

• Lead NPI projects from concept to mass production release.
• Develop and establish assembly processes for new connector products and lines.
• Define process flow, methods, and production plans based on volumes and customer requirements.
• Coordinate with cross-functional teams to ensure timely project execution and launches.
• Conduct DFM reviews to assess manufacturability and cost efficiency.
• Identify process improvements and manufacturing solutions.
• Coordinate with suppliers and machine makers, including overseas partners.
• Procure and qualify assembly and inspection equipment and monitor performance.
• Drive advanced manufacturing technologies and continuous improvement initiatives.
• Ensure smooth transfer of qualified NPI processes to mass production.
• Maintain technical documentation and ensure compliance with standards.

Skills

NPI project management

Cross-functional coordination

Problem solving

Technical troubleshooting

English communication

Mandarin (advantage)

Education

Bachelor's Degree in Mechanical Engineering

Diploma in Manufacturing/Mechatronics or related

Tools

HIPOT testers

CCD vision inspection systems

Mylar CCD inspection systems

Automated testing solutions

Job description

Johor Bahru, Malaysia

Job Responsibilities

1. NPI Project Management and Process Development

• Lead NPI projects from initial concept and process feasibility assessment through process development, qualification, validation, and mass production release.
• Develop and establish assembly processes for new connector products, including semi-automated and fully automated production lines.
• Develop process flow, manufacturing methods, and production plans based on committed monthly production volumes and customer requirements.
• Coordinate with cross-functional teams to ensure timely project execution and successful product launches.

2. DFM Review and Process Feasibility

• Conduct Design for Manufacturing (DFM) reviews with cross-functional teams to assess product manufacturability, process feasibility, and potential manufacturing risks.
• Recommend process improvements and manufacturing solutions to enhance product quality, productivity, and cost efficiency.
• Review product specifications, assembly requirements, and tooling concepts before initiating equipment development.

3. Equipment and Tooling Development

• Define equipment and tooling requirements for new product assembly and inspection processes.
• Coordinate with local and overseas machine makers, particularly suppliers in China, for equipment design, fabrication, installation, commissioning, and qualification.
• Develop and qualify assembly and inspection equipment, including HIPOT testers, CCD vision inspection systems, Mylar CCD inspection systems, and other automated testing solutions.
• Monitor equipment performance and ensure that machines meet process specifications, quality standards, and production capacity requirements.

4. Process Qualification and Validation

• Conduct process trials, engineering runs, and qualification activities to verify process capability and product quality.
• Prepare and review process documentation, including process flow charts, work instructions, equipment specifications, and qualification reports.
• Troubleshoot process and equipment issues during development and qualification, implementing corrective and preventive actions as required.
• Ensure that qualified processes meet customer requirements and are ready for mass production release.

5. Advanced Process and Technology Development

• Explore and implement innovative manufacturing technologies to improve assembly capability, precision, reliability, and production efficiency.
• Develop and optimize advanced processes for compact connector designs, SMT applications, and other specialized connector manufacturing requirements.
• Support the development of laser ablation technology to selectively remove gold plating from connector terminals to facilitate solder ball attachment for SMT applications.
• Drive continuous improvement initiatives in automation, inspection, process control, and manufacturing cost reduction.

6. Mass Production Transfer and Continuous Improvement

• Ensure smooth transfer of qualified NPI processes to mass production.
• Work closely with Production, Quality, Tooling, Equipment, and other relevant departments to resolve process-related issues during ramp‑up.
• Monitor process performance and implement improvements to achieve production targets, yield, quality, and equipment utilization.
• Maintain accurate technical documentation and ensure compliance with internal manufacturing standards and customer requirements.

Job Requirements

• Bachelor's Degree or Diploma in Mechanical Engineering, Manufacturing Engineering, Mechatronics, Electrical/Electronic Engineering, or a related discipline.
• Minimum 5 years experience in NPI, process development, manufacturing engineering, or automation within the connector, electronics, or precision manufacturing industry.
• Experience in developing and qualifying semi-automated or fully automated assembly lines and inspection systems.
• Familiarity with connector assembly processes, SMT processes, automated testing equipment, CCD vision inspection, and precision tooling.
• Experience in DFM reviews, equipment qualification, process validation, and new product mass production transfer.
• Ability to coordinate with cross-functional teams and local or overseas equipment suppliers.
• Strong problem-solving, project coordination, and technical troubleshooting skills.
• Good communication skills in English; proficiency in Mandarin is an advantage for communication with China-based machine makers