Senior Electronics Process Engineer - SMT & PCBA Innovation

Leidos; Huntsville (AL); On-site; USD 116,000 - 210,000; Full time

Job summary

Leidos seeks a Senior Process Engineer in Huntsville to lead the development, ramp-up and optimization of PCBA manufacturing. You will shape processes across SMT, conformal coating, inspection, and automated test, working with cross-functional teams to ensure efficient production workflows and high yields.

The role emphasizes DFM/DFA feedback, capital equipment justification, and hands-on improvement of manufacturing processes, with opportunities to mentor junior engineers and drive lean

Qualifications

• BS degree and 12–15 years of relevant experience (or MS with 10–12 years).
• US citizenship and ability to obtain/maintain final Secret clearance.
• Resident of Huntsville, AL or willing to relocate to the Huntsville area.
• Experience in PCBA manufacturing and process development.
• Strong DFM background to optimize production efficiency.

Responsibilities

• Co-lead and develop the manufacturing engineering team for PCBA assembly and related processes.
• Lead continuous improvement projects to increase yield, throughput, and quality across the production line and specialized equipment.
• Monitor KPIs (yield, first-pass yield, cycle time, scrap, escapes) to predict trends and drive proactive process changes.
• Perform DFM/DFA reviews on new product introductions and design changes, providing feedback to design engineering.
• Develop, document, and implement new manufacturing processes, work instructions, and process control plans.
• Identify, specify, and justify capital equipment for PCBA assembly, conformal coating, and related manufacturing processes.
• Support root cause analysis, corrective action, and disposition of manufacturing and quality nonconformances.
• Partner with quality, production control, and design teams to meet delivery schedules and customer quality requirements.

Skills

PCBA manufacturing

Process development

DFM

Lean manufacturing

MES (Aegis Factory Logix)

PCB automation equipment

SMT equipment

Education

BS degree

Master's degree

High school diploma/GED

Tools

Costpoint Material Planning

Windchill PLM

Aegis Factory Logix MES

Job description

Leidos seeks a Senior Process Engineer in Huntsville to lead the development, ramp-up and optimization of PCBA manufacturing. You will shape processes across SMT, conformal coating, inspection, and automated test, working with cross-functional teams to ensure efficient production workflows and high yields.

The role emphasizes DFM/DFA feedback, capital equipment justification, and hands-on improvement of manufacturing processes, with opportunities to mentor junior engineers and drive lean