Senior Mechanical Design Engineer

OSI Engineering, Inc.; Cupertino (CA); On-site; USD 120,000 - 160,000; Full time

Job summary

OSI Engineering, Inc. is seeking an Automation & Fixture Design Engineer to lead automation development and precision fixture design for mass-production manufacturing processes.

The role focuses on cost-effective, modular fixtures and automated solutions to enhance product quality, process capability, yield, and manufacturing efficiency. The candidate will drive automation and fixture design activities, collaborate with cross-functional teams, and evaluate automation implementations with ROI

Qualifications

• 5+ years in automation and fixture design for mass production.
• Experience with machine vision, motion control, sensors, and related programming.
• BS/MS in mechanical/manufacturing/automation or related field.

Responsibilities

• Lead automation development and precision fixture design for mass-production processes.
• Advance modular fixture concepts to improve yield and reduce costs.
• Evaluate automation needs, create RFPs, and assess integrator capabilities.
• Define qualification requirements for FAT/SAT and maintain traceability/data logging.

Skills

Automation design

Fixture design

Machine vision

CAD (GD&T)

DOE & data analysis

English fluency

Independent work

Education

Engineering degree

Tools

CAD tools

PLC/IPC programming

Job description

A globally leading consumer device company headquartered in Cupertino, CA is looking for an experienced Automation & Fixture Design Engineer to lead automation development and precision fixture design for mass-production manufacturing processes involving enclosures and modules. The role focuses on designing cost-effective, modular fixtures and automated solutions to improve product quality, process capability, yield, and manufacturing efficiency.

Drive automation and fixture design activities (including machine design, vision, controls, and component fixturing) for key manufacturing processes in the enclosure and module spaces. Innovate on assembly fixture designs through brainstorming and CAD conceptualization to drive down costs and improve part yields. Work with engineering teams to identify automation needs and opportunities, provide design for automation feedback, conceptualize required automation and modular fixtures, assess associated design/schedule risk, provide new technology capability analysis, negotiate deliverables, and create proof of concept where necessary.

Work with operations teams, cross-functional product design (PD) teams, and contract manufacturers to evaluate automation and fixture implementation risk, create technical requirements/RFP packages, assess capabilities of automation integrators, provide DFM feedback, support integrator downselect activities, and estimate automation costs and capabilities. Evaluate fixture costs through comprehensive design reviews and track ROI across all projects to ensure commercial viability.

Work with integrators to drive detailed design reviews, iterate on new fixture concepts, execute proof of concept, maintain and resolve issues lists, implement data logging and traceability requirements, review control logic and programming, and define qualification requirements for FAT/SAT. Develop modular designs for component fixturing to ensure fixtures can be reused year over year, maximizing capital equipment reuse.

Design precision fixtures specifically tailored for advanced automation stations like laser welding, precision dispensing (gluing), insert molding, and automated adhesive/masking tape application. Maintain deep knowledge of equipment capabilities and key process drivers; keep abreast of the latest industrial developments and leverage new technologies in novel ways to enable improved capabilities. Consistent overseas and occasional domestic travel required, on a quarterly basis.

Key Qualifications:

• 5+ years of experience working on automation, robotics applications, and fixture design for mass production applications.
• Machine and fixture design expertise.
• Experience designing, deploying, qualifying, supporting, and project managing automated manufacturing process lines that incorporate machine vision (including cameras, lighting, and programming), motion control (including actuators, motors, pneumatics) and sensors, with expertise in most of those component groups.
• Extensive experience using CAD to review and design mechanical components, complex assemblies, and precision fixtures, and create proper engineering part drawings using GD&T practices.
• Ability to reconcile DFM feedback with design goals, anticipate risk and identify mitigation opportunities, drive root cause/corrective action and process optimization activities to closure efficiently with proper design of experiment (DOE) practices and detailed data analysis using statistical methods such as process capability, correlation, GR&R, etc. and software such as JMP, Matlab, etc.
• Fluent spoken and written English skills with an ability to articulate complex, technical concepts and issues in a clear and concise manner to audiences of mixed backgrounds.
• Ability to work independently on a variety of demanding, concurrent projects that often require creative solutions and intellectual curiosity.

Desired Qualifications:

• Expertise working on vision-guided assembly, precision dispense, and laser welding applications in a mass production environment.
• Experience designing scalable, modular fixtures that can be reused across multiple product generations.
• Expertise with one or more major brand six-axis industrial robots (Fanuc, ABB, etc.) and PLCs/IPCs (Mitsubishi, Beckhoff, Siemens, etc.) along with associated programming languages.
• Expertise with motion control components, machine vision components, and sensors.
• Experience working overseas with international supply chains and contract manufacturers.
• Fluency in Mandarin Chinese is a plus.

Education:

BS/MS in engineering (mechanical, manufacturing, automation, mechatronics, robotics, or equivalent).