Director/Senior Engineering Manager PCBA, System Integration, Process & Manufacturing Engineering (San Jose)
Director / Senior Engineering Manager PCBA, System Integration, Process & Manufacturing Engineering
Department:
Manufacturing / Engineering
CATEGORY: Exempt - Supervisory
JOB FUNCTION :
The Senior Manager for PCBA, System Integration, Process & Manufacturing Engineering is responsible for leading cross-functional engineering teams in the development, optimization, and sustainment of manufacturing processes for printed circuit board assemblies (PCBAs), system-level integration, and final product assembly. This role ensures manufacturing operations deliver world-class quality, productivity, scalability, and cost competitiveness by driving process innovation, operational excellence, and successful new product introductions (NPIs).
QUALIFICATIONS:
Education:
- Masters degree in Mechanical, Electrical, Industrial, or Manufacturing Engineering
- 10+ years of progressive engineering experience in PCBA, system integration, and manufacturing, with at least 5 years in senior leadership role.
- Deep expertise in SMT, soldering processes, AOI/X-ray, ICT/FCT, and functional testing.
- Strong knowledge of mechanical assembly, cabling, and enclosure integration.
- Proficient in Lean Manufacturing, Six Sigma, PFMEA, DOE, and SPC.
- Exceptional leadership, problem-solving, and cross-functional collaboration skills.
- Experience with MES, ERP, and Industry 4.0 systems preferred.
Leadership & Strategic Direction
- Lead, mentor, and grow high-performing engineering teams across PCBA, system integration, process, and manufacturing engineering functions.
- Define and execute the long-term technical roadmap for manufacturing process capability, automation, and quality improvement.
- Drive a culture of continuous improvement using Lean, Six Sigma, and Industry 4.0 principles.
- Manage engineering budgets, capital equipment investments, and resource planning.
- Oversee SMT, wave solder, selective solder, conformal coating, and inspection processes (AOI, X-ray, ICT/FCT).
- Drive DFM/DFT (Design for Manufacturability/Testability) engagement with R&D and suppliers.
- Establish and maintain process control metrics (Cp, Cpk, FPY, OEE).
- Lead root cause analysis and corrective actions for PCBA-related yield or quality issues.
- Manage engineering support for electromechanical system integration, sub-assembly builds, and final product assembly.
- Develop assembly processes, tooling, fixtures, and test methods for system-level builds.
- Optimize line balancing, ergonomics, and material flow to increase throughput and reduce labor content.
- Collaborate with test engineering to integrate functional, environmental, and burn-in testing into production flow.
- Standardize manufacturing processes across production lines to ensure scalability and repeatability.
- Implement digital manufacturing tools, MES integration, and real-time process monitoring.
- Conduct PFMEA, DOE, SPC, and process validation to ensure robust production readiness.
- Identify and implement cost-saving opportunities through yield improvement, scrap reduction, and automation.
- Lead cross-functional readiness reviews and pilot builds for new products.
- Develop process documentation, work instructions, and operator training programs.
- Ensure smooth transition from engineering builds to mass production with minimal quality issues.
- Ensure compliance with IPC standards (IPC-A-610, J-STD-001), ESD controls, and regulatory requirements (RoHS, REACH, ISO 9001).
- Maintain equipment calibration, process documentation, and operator certifications.
- First-pass yield (FPY) improvement and defect rate reduction.
- On-time and successful NPI launches.
- OEE (Overall Equipment Effectiveness) and throughput gains.
- Manufacturing cost savings from process and design improvements.
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