Process Engineer

sensata; Vista (CA); On-site; USD 99,000 - 136,000; Full time

Job summary

Sensata is seeking a Process Engineer in Vista, CA to develop and optimize manufacturing processes for electromechanical products. You will work with design engineers, vendors, and program managers to improve manufacturability, cost, and quality.

You will lead process development, support APQP deliverables, and drive readiness from NBO to ramp-up while aligning with cost and delivery targets. ITAR/EAR eligibility is required.

Qualifications

• Bachelor's degree in engineering or equivalent
• Strong communication and presentation skills
• Ability to work in a fast-paced environment with multiple tasks

Responsibilities

• Develop or modify manufacturing processes to increase product performance and efficiency.
• Define specifications for production equipment and interact with suppliers to meet specs.
• Collaborate with cross-functional teams to enable successful product launches.
• Provide DFM feedback to design engineering to improve manufacturability.
• Develop new or improved processes and equipment to meet cost targets and performance requirements.
• Support APQP deliverables like PFDs, PFMEAs, CPs, MSA, and PPAP readiness.
• Qualify high-performance test systems including electrical, thermal, and environmental testing.
• Lead process engineering in cross-functional NPD programs.

Skills

Team player

Strong communication

Strong organization

Ethics and integrity

Self-accountable

Interpersonal & collaboration

Education

Bachelor's degree in Engineering or related field

Tools

Microsoft Office

Job description

The Process Engineer is responsible for developing or modifying manufacturing processes to increase product performance, improve manufacturing efficiency and boost profits. This position works closely with design engineers, equipment vendors, program managers, marketing, and quality engineers to support the development of new electromechanical products. They are responsible for providing the overall process design and suggesting measures to improve product design for manufacturability. This includes the development of new equipment and process flows as well as developing cost estimates for labor and capital. They will also provide ongoing sustaining support to production lines at our global make sites.

General Responsibilities

• Key participant in the development of new production processes and/or adapt existing production processes for assembly, calibration and testing
• Define specifications for production equipment and interact with mechanization (in house) and/or equipment suppliers to ensure equipment will meet specifications
• Key participant in global new product development project teams to enable successful launch of new products
• Collaborate with other departments on process specifications, quality aspects, product specifications and continuity of equipment
• Influence product designs during new product development phase to ensure economical and defect free manufacture
• Developing new or improved manufacturing and testing processes that are necessary to achieve the performance and cost requirements of future device applications
• Organize the arranging of sample lines and process development equipment
• Key participant in advanced quality planning activities
• Coordinates all functional requirements, the reviewing of designs and debugging /qualifying new high volume assembly /test equipment or tooling
• Transferring knowledge to make site personnel
• Support improvement projects to reduce cycle time, defects and manufacturing costs
• Work with suppliers and contract manufacturers to ensure processes are capable, have sufficient controls in place, can meet out delivery requirements, and meet our cost targets
• Evaluate technical capabilities including tooling design, build experience, maintenance program, processes and process controls, cell automation- if required, quality control systems, and material knowledge

Experience / Qualifications

• A university degree required (i.e. Bachelors degree) or equivalent relevant work experience
• Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands
• Strong communication skills; oral, written and presentation
• Strong organization, planning and time management skills to achieve results
• Strong personal and professional ethical values and integrity
• Holds self-accountable to achieving goals and standards
• Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel)
• Strong interpersonal & collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers

Support the development of advanced manufacturing processes and automation for BLDC Motors and Voice Coil Actuators, including winding, magnet assembly, precision bonding, soldering, laser welding, and actuator assembly.

Drive innovation in motor manufacturing techniques (e.g., high-speed winding, precision balancing, coil insertion, magnetization, and VCA assembly processes).

Support execution of APQP deliverables for new product programs, including:

• Process Flow Diagrams (PFD)
• PFMEA (Process Failure Mode & Effects Analysis)
• Control Plans
• Measurement System Analysis (MSA)
• PPAP readiness and submission support

Develop and qualify high-performance test systems for motors and VCAs including:

• Electrical performance testing (torque, speed, efficiency)
• Thermal and environmental validation
• End-of-line functional testing with automated data capture to ensure processes meet AS9100 and customer-specific quality requirements.

Serve as the process engineering lead on cross-functional NPD programs.

Provide DFM/DFA feedback to design engineering to optimize product manufacturability.

Drive manufacturing readiness from NBO through SOP and ramp-up, ensuring alignment with cost, quality, and delivery targets.

This position requires eligibility to obtain authorization under the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Non-US Persons, as defined in the ITAR and EAR, may not be eligible to obtain authorization.

#LI-MY1 #LI-Onsite

Base Salary Range: $99,040.00 - $136,180.00

At Sensata, our employees are the key to our success and growth. We recognize that each individual brings their own unique experience, therefore the base salary range information shown above is a general guideline only. Sensata considers several factors when extending an offer, including, but not limited to, a candidate's experience an