Senior NPI Engineer — Hardware Manufacturing & Automation

Sesame; San Francisco (CA); Hybrid; USD 180,000 - 240,000; Full time

Benefits offered by this job

401(k) matching

Health, vision, and dental coverage

Unlimited PTO

FSA

Stock options

Job summary

Sesame is seeking an experienced NPI Engineer to lead manufacturing solutions with contract manufacturers in Asia, driving automation, tooling, and validation through prototype to mass production. You will own FATP readiness, coordinate with global supply chain, and partner with integrators to develop advanced automation and tooling, ensuring quality and cost targets while optimizing capacity and OEE.

Expect up to 40-50% onsite time.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, or equivalent experience.
• 10+ years of hardware program management experience, ideally in consumer electronics.
• Up to 40-50% onsite time at contract manufacturing partner.
• Deep understanding of phase gate methodology, from prototype through high volume manufacturing.
• Proficiency in SPC, capability (CPK), and capacity modeling (cycle time, throughput, yield, OEE).
• Strong mastery of Six Sigma principles and DFX (Design for Excellence) methodologies.
• Demonstrated success in delivering hardware products from concept to mass production.

Responsibilities

• Manage onsite delivery of manufacturing solutions at contract manufacturers in Asia.
• Own FATP manufacturing readiness and coordinate across the global supply chain.
• Partner with third-party integrators to develop and validate advanced automation and specialized tooling.
• Monitor and optimize production capacity and efficiency metrics including UPH, throughput, yield, and OEE.
• Drive technical transfers and manage vendor relationships to ensure high-quality service delivery.
• Implement SPC and capability (CPK) monitoring systems to ensure process stability and quality.
• Land innovation into shipping products through cross-functional collaboration with engineering teams.
• Spearhead DFX initiatives—DFM/DFA—to optimize product designs for high-volume manufacturing, assembly, and cost-efficiency.
• Lead statistical tolerance analysis and GD&T implementation to ensure precision at the CM level.
• Collaborate with R&D teams and external suppliers to influence design decisions early in the product lifecycle.
• Deploy manufacturing systems to support quality management, genealogy, and SPC.
• Evaluate 2D/3D design documentation and specifications for manufacturing/assembly requirements.
• Architect manufacturing solutions, including fixturing and automation.
• Own specifications, budgets and tool delivery schedules.

Skills

Hardware program management

Phase gate

SPC/CPK

Six Sigma Green Belt

Onsite liaison

Lean manufacturing

GD&T

Education

Bachelor’s degree in Mechanical/Industrial Engineering

Job description

About Sesame

Sesame believes in a future where computers are lifelike - with the ability to see, hear, and collaborate with us in ways that feel natural and human. With this vision, we're designing a new kind of computer, focused on making voice agents part of our daily lives. Our team brings together founders from Oculus and Ubiquity6, alongside proven leaders from Meta, Google, and Apple, with deep expertise spanning hardware and software. Join us in shaping a future where computers truly come alive.

About the Role

As an NPI Engineer, you will lead the deployment of innovative solutions, partnering with Asian manufacturing integrators to develop automation, tooling, and validation processes. This role is critical for leading programs from groundbreaking through mass production, ensuring that complex manufacturing challenges are resolved while meeting quality, cost, and delivery targets. A successful candidate will be able to manage onsites manufacturing engineering deliverables, inclusive of architecting required solutions and establishing targets to meet the business need.

Responsibilities:

• Manage onsite delivery of manufacturing solutions at contract manufacturers in Asia.

• Own FATP manufacturing readiness and coordinate across the global supply chain, including component suppliers, operations teams, and internal engineering partners.

• Partner with third-party integrators to develop and validate advanced automation and specialized tooling.

• Monitor and optimize production capacity and efficiency metrics including UPH, throughput, yield, and OEE.

• Drive technical transfers and manage vendor relationships to ensure high-quality service delivery.

• Implement SPC and capability (CPK) monitoring systems to ensure process stability and quality.

• Land innovation into shipping products through effective cross-functional collaboration with engineering teams.

• Spearhead DFX (Design for Excellence) initiatives—specifically DFM/DFA—to optimize product designs for high-volume manufacturing, assembly, and cost-efficiency.

• Lead statistical tolerance analysis and the implementation of GD&T to ensure precision and process capability at the CM level.

• Collaborate with R&D teams and external suppliers to influence design decisions early in the product lifecycle, proactively addressing manufacturability challenges.

• Deploy manufacturing systems to support quality management, genealogy, and statistical process control.

• Evaluate 2D/3D design documentation and technical specifications to ensure full compliance with rigorous manufacturing and assembly requirements.

• Architect manufacturing solutions, inclusive of fixturing and automation requirements.

• Owner of specifications and requirements, budgets and manufacturing tool delivery schedules.

Required Qualifications:

• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, or equivalent experience.

• 10+ years of hardware program management experience, ideally in consumer electronics.

• Up to 40-50% onsite time at contract manufacturing partner

• Deep understanding of phase gate methodology, from prototype through high volume manufacturing.

• Proficiency in SPC, capability (CPK), and capacity modeling (cycle time, throughput, yield, OEE).

• Strong mastery of Six Sigma principles and DFX (Design for Excellence) methodologies. Six Sigma Green Belt or equivalent.

• Demonstrated success in delivering hardware products from concept to mass production.
  

Preferred Qualifications:

• 15+ years of experience in leading-edge consumer electronics manufacturing.

• Experience leading organizations from groundbreaking through mass production.

• Deep expertise in architecting solutions with Asian manufacturing integrators.

• Advanced knowledge of Lean Manufacturing or the Toyota Production System.

• Six Sigma Black Belt

Sesame is committed to a workplace where everyone feels valued, respected, and empowered. We welcome all qualified applicants, embracing diversity in race, gender, identity, orientation, ability, and more. We provide reasonable accommodations for applicants with disabilities. Contact [e-mail] for assistance.

Full-time Employee Benefits:

• 401 (k) max employer match: 3.5% of compensation

• 100% employer-paid health, vision, and dental benefits for you and your dependents

• Unlimited PTO and sick time

• Flexible spending account with employer matching up to $1,650/year (medical FSA)

• Guardian Employee Assistance Program (EAP)

• Opportunity to share in the company's success with competitive stock options

Benefits do not apply to contingent/contract workers.