Lead Avionics DFMA Engineer

Mach Industries Inc.

Huntington Beach, Northern (CA, KY)

Hybrid

USD 140,000 - 180,000

Full time

3 days ago

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Job summary

Mach Industries in Huntington Beach, CA, is seeking a Lead Manufacturing Engineer, Avionics, to own the Avionics DFMA guide and lead DFMA-focused design for manufacturability across PCBAs, wire harnesses and enclosures.

You will push R&D on new materials and processes, mentor engineers, and drive value engineering with suppliers and contract manufacturers. The role requires 8+ years in avionics/manufacturing and a BS in engineering.

Qualifications

BS in Electrical, Mechanical, Manufacturing or Industrial Engineering, or equivalent.
8+ years in avionics, PCBA or harness manufacturing or design engineering. This includes taking hardware from design into production at rate in aerospace, defense, automotive or consumer electronics.
Working knowledge of IPC-A-610, J-STD-001 and IPC/WHMA-A-620.
Experience with SMT processes, box build and electrical test.
A track record of writing design standards, guides, process specs.
Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics and ROI.
Working knowledge of GD&T (ASME Y14.5) and tolerance stack-ups.
Skilled in 3D CAD (NX, CATIA, SolidWorks or similar) and comfortable in ECAD tools.

Responsibilities

Own the Avionics DFMA guide.
Write DFMA/DFM/DFA/DFT rules for PCBAs, wire harnesses, connectors and avionics enclosures (box build).
Set connector retention and mate-assurance standards: CPA clips, TPA locks, full-mate indicators, color-coded CPAs.
Define how each connection is checked at the station: push-pull-push checks, vision checks, and mate-detect tests.
Define the DFMA sign-off criteria for design gates and hold programs to them.
Set and track DFMA metrics: part count, unique connector count, assembly and test time, first-pass yield and cost.
Keep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.
Review vehicle and electrical architecture at concept, before designs lock: box placement, harness layout and connector strategy.
Lead static and kinematic assembly studies (virtual builds) before hardware exists. Check harness routing, install paths, and hand and tool access to mate each connector and seat its CPA.
Drive content reduction (fewer connectors, wires and boards), simpler assembly, build-in-quality and ergonomic access. Push for automation-friendly features.
Define avionics poka-yoke standards, for example: connector keying and clocking; two-stage CPA clips and TPA locks; blind-mate or tool-less installation.
Lead value engineering on released designs: challenge assumptions and take out cost.
Enable trade studies and make vs. buy.
Build should-cost, cycle-time and rate models that show how design choices affect cost, capital investment, schedule and quality.
Write the manufacturing requirements in RFQ packages for contract manufacturers and help evaluate supplier quotes.
Lead R&D on automated harness fabrication, flex and rigid-flex circuits that replace harnesses, simpler interconnects, and faster-curing potting and coatings.
Develop connector and CPA designs that confirm a full mate automatically, through vision or electrical mate detection.
Plan and run designed experiments (DOE). Build test articles, test to failure, analyze results with sound statistics, and publish findings.
Co-develop new components, processes and equipment with suppliers, contract manufacturers, equipment makers, universities and national labs.
Lead manufacturing trials during prototype / validation builds to prove new processes.