Senior Process Engineer

00181 Dynetics Tech Sol, Inc; 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

Looking for an opportunity to make an impact? At Leidos, we deliver innovative solutions through the efforts of our diverse and talented people who are dedicated to our customers’ success. We empower our teams, contribute to our communities, and operate sustainably. Everything we do is built on a commitment to do the right thing for our customers, our people, and our community. Our Mission, Vision, and Values guide the way we do business. Your greatest work is ahead! We are seeking a motivated, hands‑on Senior Process Engineer to play a key role in the development, implementation, and ramp‑up of a new, state‑of‑the‑art electronics manufacturing facility. This position offers an exciting opportunity to help shape manufacturing capabilities from the ground up, supporting facility layout development, equipment installation, commissioning, and process optimization across Surface Mount Technology (SMT), conformal coating, inspection, and automated test operations. The candidate will collaborate with Manufacturing Engineering, Industrial Engineering, Quality, Facilities, and Operations teams to establish efficient production workflows, optimize equipment utilization, and ensure seamless transitions from PCBA manufacturing through subassembly and final integration. If this sounds like the kind of environment where you can thrive, keep reading! Leidos Defense Systems Sector / Manufacturing provides a diverse portfolio of systems, solutions, and services covering land, sea, air, space, and cyberspace for customers worldwide. Solutions for Defense include enterprise and mission IT, large‑scale intelligence systems, command and control, geospatial and data analytics, cybersecurity, logistics, training, and intelligence analysis and operations support. Our team is solving the world’s toughest security challenges for customers with “can’t fail” missions.

Primary Responsibilities

• Co‑lead and develop the manufacturing engineering team supporting PCBA assembly and complimentary processes such as selective solder, press‑fit, conformal coating, board washing, etc..
• Drive continuous improvement projects to increase yield, throughput, and quality across the production line and specialized equipment.
• Monitor manufacturing 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.
• Support quality engineering in process development and onsite audits Establish and monitor quality objectives of the production process Mentor and develop junior engineers in process development, root cause analysis,and mitigation

Basic Qualifications

• Requires a BS degree and 12-15 years of prior relevant experience or Masters with 10-12 years of prior relevant experience.
• In lieu of a degree, a highschool diploma/GED with 15 years of experience will be considered
• Must be a U.S. Citizen and be able to obtain/maintain a finalSecret Clearance
• Previous experience working in PCBA manufacturing and process development
• Strong background in Design for Manufacturability (DFM) to optimize product designs for production efficiency.
• Candidate must be a resident of Huntsville, Alabama or be willing to relocate to the Huntsville, Alabama area.

Preferred Qualifications

• Familiarity with IPC requirements (J-STD-001 and IPC-A-610)
• Experience with electronics used on launch vehicles, targets, or missile components such as PCBAs, cable harnesses, or electro‑mechanical assemblies
• Experience with Costpoint Material Planning software and/or Windchill product lifecycle management software is a plus.
• Experience working in a mid to high volume manufacturing environment
• Ability to provide Rough Order of Magnitude (ROM) estimates, Basis of Estimate (BOE) documents, and other information to support proposal efforts
• Demonstrated success in implementing lean principles to reduce waste and improve efficiency.
• Experience in using Manufacturing Execution Systems (MES) such as Aegis Factory Logix is also a plus.
• Hands‑on experience with PCBA automation equipment, such as SMT mounters, selective solder, board wash, press‑fit, AOI, and general soldering equipment.

Pay Range

Pay Range $116,350.00 - $210,325.00

The Leidos pay range for this job level is a general guideline only and not a guarantee of compensation or salary. Additional factors considered in extending an offer include (but are not limited to) responsibilities of the job, education, experience, knowledge, skills, and abilities, as well as internal equity, alignment with market data, applicable bargaining agreement (if any), or other law.

Pay and Benefits

Employment benefits include competitive compensation, Health and Wellness programs, Income Protection, Paid Leave and Retirement.

Additional details are available here.

Securing Your Data

Leidos will never ask you to provide payment‑related information at any part of the employment application process.

And Leidos will communicate with you only through emails that are sent from a Leidos.com email address.

If you receive an email purporting to be from Leidos that asks for payment‑related information or any other personal information, please report the email to [e-mail].

Commitment and Diversity

All qualified applicants will receive consideration for employment without regard to sex, race, ethnicity, age, national origin, citizenship, religion, physical or mental disability, medical condition, genetic information, pregnancy, family structure, marital status, ancestry, domestic partner status, sexual orientation, gender identity or expression, veteran or military status, or any other basis prohibited by law.

Leidos will also consider for employment qualified applicants with criminal histories consistent with relevant laws.