Process Development Engineer

NPAworldwide; Kulai; On-site; MYR 89,000 - 167,000; Full time

Job summary

NPAworldwide is seeking an experienced engineer to lead New Product Introduction (NPI) projects from concept and feasibility through process development, qualification, validation, and mass production release.

You will develop assembly processes for connector products, coordinate cross-functional teams, and drive continual improvements in automation, testing, and tooling. The role emphasizes DFM reviews and successful transfer to mass production.

Qualifications

• Bachelor's degree or diploma in a relevant engineering discipline is required.
• Experience in NPI, process development, manufacturing engineering, or automation is preferred.
• Experience with semi-automated or fully automated assembly lines and inspection systems is advantageous.

Responsibilities

• Lead NPI projects from concept through process development, qualification, validation, and mass production release.
• Develop and establish assembly processes for new connector products, including semi-automated and fully automated lines.
• Coordinate with cross-functional teams to ensure timely project execution and successful product launches.
• Conduct DFM reviews to assess manufacturability, feasibility and risks.
• Define equipment and tooling requirements; coordinate with local and overseas suppliers for design, fabrication, installation and qualification.
• Develop and qualify assembly and inspection equipment (HIPOT, CCD vision, Mylar CCD).
• Perform process qualification and validation, including trials and engineering runs; prepare qualification reports.

Skills

Project management

Process development

Cross-functional collaboration

Automation

DFM review

Equipment qualification

Mass production transfer

Troubleshooting

Education

Bachelor's Degree or Diploma in Mechanical Engineering, Manufacturing Engineering, Mechatronics, Electrical/Electronic Engineering, or a related discipline

Tools

HIPOT testers

CCD vision inspection systems

Mylar CCD inspection systems

Job description

• 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.


• 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


• 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.


• 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.


• 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.


• 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 Description

• 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.


• 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


• 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.


• 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.


• 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.


• 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.

Qualifications

• 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

Why Is This a Great Opportunity

• End-to-End NPI Project Exposure Offers the opportunity to lead New Product Introduction (NPI) projects from initial concept and feasibility assessment through process qualification and mass production launch.


• Advanced Automation and Technology Development Provides hands-on exposure to automated assembly lines, CCD vision inspection systems, precision tooling, SMT applications, and advanced manufacturing technologies.


• Cross-Functional and International Collaboration Involves working closely with Production, Quality, Equipment, Tooling teams, and overseas machine makers, particularly suppliers in China.


• Technical Expertise and Problem-Solving Development Strengthens expertise in Design for Manufacturing (DFM), process validation, equipment qualification, troubleshooting, and continuous improvement in precision connector manufacturing.


• Career Growth in Advanced Manufacturing Offers a valuable platform for experienced engineering professionals to contribute to new product launches, manufacturing innovation, production efficiency, and cost optimisation within the electronics and connector industry.