Process Engineer - PCBA (SMT & Assembly)

Ultimate Staffing; Milpitas (CA); On-site; USD 110,000 - 150,000; Full time

Job summary

Ultimate Staffing seeks a Process Engineer for a client in Milpitas, CA. This full-time, direct-hire onsite role focuses on manufacturing process control, troubleshooting, and quality issue resolution for PCBA assemblies.

You will partner with Manufacturing Engineering to develop, implement, and continuously improve production processes, support NPI, equipment management, and cross-functional collaboration across Production, Quality, Supply Chain, and R&D.

Qualifications

• Bachelor’s degree in Engineering or equivalent.
• 5–7 years of experience in manufacturing engineering.
• Experience in PCBA/SMT environments.

Responsibilities

• Develop, validate, and optimize PCBA manufacturing processes (SMT and box build).
• Optimize production layouts to improve efficiency, throughput, and productivity.
• Establish process parameters, controls, and standard methodologies.
• Support product launches from prototype through full-scale production (NPI).
• Select, qualify, and validate SMT equipment; implement preventive maintenance.
• Analyze defects and lead corrective actions using 8D, RCA, and FMEA.

Skills

PCB assembly

SPC

Data-driven decisions

Problem solving

Project management

Leadership

Communication

Education

Bachelor's degree in Engineering

Job description

We are currently seeking a Process Engineer to join a client in Milpitas. This is a full-time, direct hire position. The role is 100% onsite.

The Process Engineer is responsible for executing engineering activities that support manufacturing process control, troubleshooting, and resolution of quality issues. This role partners closely with Manufacturing Engineering to develop, implement, and continuously improve production processes, ensuring efficiency, quality, and scalability. The position also interfaces cross-functionally to support the development, installation, and maintenance of advanced manufacturing methods and controls.

Key Responsibilities

1. Process Development & Optimization

• Develop, implement, and validate manufacturing processes for PCBA assembly, including SMT and box build.
• Optimize production line layouts to improve efficiency, throughput, and productivity.
• Establish process parameters, controls, and standard methodologies.
• Perform time studies and capacity analysis to support production planning.

2. New Product Introduction (NPI)

• Support product launches from prototype through full-scale production.
• Review Gerber files, BOMs, and assembly drawings to ensure manufacturability (DFM/DFA).
• Create process flows, work instructions, and control plans.
• Coordinate and execute pilot builds, process validation, and production readiness activities.

3. Equipment & Tooling Management

• Select, qualify, and validate SMT equipment (e.g., printers, SPI, pick-and-place, reflow ovens, AOI).
• Program and optimize production equipment, including:
  • SMT platforms (e.g., ASMPT, Panasonic, Fuji)
  • Wave soldering machines (e.g., Electrovert, SEHO, ERSA)
  • Conformal coating systems (e.g., PVA, Nordson)
• Establish and maintain preventive maintenance programs.
• Troubleshoot equipment and process-related issues to minimize downtime.

4. Quality & Continuous Improvement

• Analyze defects and lead corrective actions using methodologies such as 8D, RCA, and FMEA.
• Monitor and improve key performance indicators (KPIs), including FPY, OEE, yield, scrap, and cycle time.
• Implement mistake-proofing (poka-yoke) solutions and drive continuous improvement initiatives.

5. Documentation & Compliance

• Develop and maintain SOPs, process documentation, and engineering change records.
• Ensure compliance with industry standards, including IPC-A-610.
• Maintain accurate process data within ERP/MES systems.

6. Cross-Functional Collaboration

• Partner with Production, Quality, Supply Chain, and R&D teams to drive operational success.
• Interface with customers on technical matters, including audits and process reviews.
• Provide training and technical guidance to operators and technicians.

Qualifications

Education

• Bachelor's degree in Engineering or equivalent combination of education and experience.

Experience

• 5-7 years of experience in manufacturing engineering, preferably in PCBA/SMT environments.

Core Competencies

Technical Skills

• Strong knowledge of PCB assembly processes, including SMT and PTH.
• Expertise in PCBA manufacturing and process development.
• Experience with Statistical Process Control (SPC) and data-driven decision-making.

Professional Skills

• Strong problem-solving and analytical thinking
• Effective communication and collaboration skills
• Project management capabilities
• Decision-making and leadership ability
• Continuous improvement and innovation mindset

All qualified applicants will receive consideration for employment without regard to race, color, national origin, age, ancestry, religion, sex, sexual orientation, gender identity, gender expression, marital status, disability, medical condition, genetic information, pregnancy, or military or veteran status. We consider all qualified applicants, including those with criminal histories, in a manner consistent with state and local laws, including the California Fair Chance Act, City of Los Angeles' Fair Chance Initiative for Hiring Ordinance, Los Angeles County Fair Chance Ordinance, and San Francisco Fair Chance Ordinance.