{"id":1721678,"url":"https://alion.io/job/viavi-solutions-senior-manufacturing-engineer","title":"Senior Manufacturing Engineer","company":{"id":58886,"name":"VIAVI Solutions","domain":"viavisolutions.com","url":"https://alion.io/company/viavi-solutions","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Workday","truth_index":{"grade":"B","score":77,"open_postings":33,"ghost_share":0,"stale_share":0.909,"repost_share":0,"time_to_fill_p50_days":32,"computed_at":"2026-10-19T05:45:15Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Indianapolis, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":84000,"max_usd":159000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":5578},"experience_years_min":5,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"SolidWorks","optional":false},{"name":"Agile","optional":true}],"status":"live","first_seen_at":"2026-09-28T00:00:00Z","employer_posted_date":"2026-09-28","last_verified_at":"2026-10-19T09:57:22Z","board_verified":true,"closed_at":null,"days_open":21,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":21},"description":"Summary:\nVIAVI (NASDAQ: VIAV) is a global provider of network test, monitoring and assurance solutions for telecommunications, cloud, enterprises, first responders, military, aerospace, and railway. VIAVI is also a leader in light management technologies for 3D sensing, anti-counterfeiting, consumer electronics, industrial, automotive, government and aerospace applications.We are the people behind the products that help keep the world connected at home, school, work, at play, and everywhere in between. VIAVI employees are passionate about supporting customer success and we welcome people who bring their best every day to the company - to question, to collaborate and to push for solutions that will delight our customers.\nDuties & Responsibilities:\nSenior Manufacturing Engineer\nVIAVI Solutions - Fiber Instruments NPI | Indianapolis, IN\nSummary\nJoin the founding members of a new Operations Engineering NPI team in Indianapolis, chartered with bringing VIAVI's next generation of fiber optic test instruments - OTDR modules, handheld fiber testers, optical power meters and sources, and automated fiber certification platforms - from R&D into volume manufacturing. As the Senior Manufacturing Engineer, you own how these products get built: the process flow, the tooling and fixturing, the work instructions, and the qualification that proves the line can produce them repeatably and at cost. You will work in close partnership with R&D in Indianapolis and VIAVI's prime fiber optic design center in St. Etienne, France, and with our internal and contract manufacturing factories.\nNote to Applicants: This is a factory process and industrialization role. It is NOT a product design, field service, or production supervision position.\nProfessional Growth and Tooling\nWe're building this team from the ground up and investing in the right engineer to help shape it:\nPhotonics Process Training: Structured ramp-up on fiber handling, splicing, connectorization, and optical cleanliness control if you are coming from an adjacent electromechanical or electro-optical background.\nGreenfield Ownership: Define the process architecture, documentation standards, and tooling strategy for a portfolio, rather than inheriting someone else's.\nGlobal Exposure: Direct working relationships with an international R&D organization and with contract manufacturing partners.\nEssential Duties and Responsibilities\nManufacturing Process Definition\nDefine the build process: Own end-to-end manufacturing process design for new fiber optic instruments - process flow, assembly sequence, station definition, routings, and work content - from PCBA integration through optical subassembly, final assembly, calibration, and pack-out.\n Optical assembly processes: Develop and qualify processes for fiber handling and routing, bend radius control, splicing and connectorization, optical connector integration (SC/LC/FC, UPC/APC), adhesive dispense and cure, and optical subassembly alignment.\nContamination control: Establish connector end-face inspection and cleaning protocols to industry standards and the broader cleanliness discipline that fiber optic assembly yield depends on.\nLine design and capacity: Define line layout, station ergonomics, cycle time, line balance, and labor content; model capacity against forecast volumes and identify the constraints before they bite.\nDesign for Manufacturing and Assembly\nPartner with R&D in Indianapolis and St. Etienne from concept phase forward, providing structured DFM/DFA feedback on part design, tolerance stack-up, fastening and joining methods, optical accessibility, and assembly sequence.\nParticipate in design reviews as the manufacturing voice; quantify the cost and yield impact of design choices rather than asserting them.\nDrive design changes that reduce part count, assembly time, scrap risk, and the need for skilled manual operations.\nTooling, Fixturing, and Equipment\nSpecify, design, procure, and qualify assembly tooling, fixtures, jigs, and process equipment, working with internal resources and external suppliers.\nPartner with the Senior Test Engineer to ensure assembly fixturing and test fixturing interfaces are compatible and CM-ready.\nDevelop and execute equipment qualification and process validation protocols; own the data that proves a process is capable before release.\nBuild capital justifications for tooling and equipment in support of the Operations Engineering Manager's capital plan.\nDocumentation and Process Control\nAuthor and maintain manufacturing documentation: work instructions, visual aids, process specifications, assembly drawings, routings, and inspection criteria.\nLead PFMEA development and translate the output into control plans with defined process controls, reaction plans, and inspection points.\nApply statistical methods - SPC, process capability (Cpk), and designed experiments - to characterize and control critical processes.\nManage engineering change orders (ECOs) affecting manufacturing, including BOM structure, routing, and documentation impact.\nPilot Build, Launch, and Transfer\nPlan and lead prototype, pilot, and first-article builds; capture issues, drive them to root cause, and close them before production release.\nPrepare the complete manufacturing transfer package and lead the transfer of new products to internal VIAVI factories and contract manufacturing partners.\nTrain factory and CM engineering and production staff on new processes; validate that the receiving site can execute the process as designed.\nSupport production ramp on site, resolving process issues in real time and confirming yield and cycle time targets are met.\nSustaining and Continuous Improvement\nMonitor yield, scrap, rework, and cycle time across the portfolio; lead root cause investigation and permanent corrective action for manufacturing escapes.\nDrive cost reduction and productivity improvement using Lean and Six Sigma methods.\nMaintain process documentation and tooling throughout the product lifecycle, including support for component obsolescence and second-source qualification.\nCollaboration and Leadership\nCommunicate effectively with R&D (Indianapolis and St. Etienne), Product Line Management, Quality, Supply Chain, and contract manufacturing partners, including across time zones.\nAs a founding member of a new team, help establish team norms and practices in addition to individual technical delivery.\nReport status against commitments, demonstrate self-directed initiative, and mentor less experienced engineers and technicians as the team grows.\nPre-Requisites / Skills / Experience Requirements:\nRequired Qualifications\nEducation\nBachelor of Science in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Electrical Engineering, or a related technical field.\nExperience and Technical Skills\n5+ Years in Manufacturing or NPI Engineering: Developing and qualifying assembly processes for electronic, electromechanical, or electro-optical products.\nNPI Toolset: Demonstrated command of DFM/DFA, PFMEA, control plans, first article inspection, process capability analysis, and build readiness reviews.\nDocumentation Discipline: Proven ability to author clear, unambiguous work instructions and process specifications that a production operator can actually follow.\n Tooling and Fixture Development: Experience specifying and qualifying assembly tooling and fixtures; familiarity with 3D CAD (SolidWorks, Creo, or equivalent).\nPrecision Assembly: Hands-on experience with high-precision, low-tolerance assembly involving delicate components and contamination-sensitive processes.\n Statistical Methods: Practical application of SPC, Cpk, and root cause problem-solving methodologies (8D, fishbone, 5-Why).\nDemonstrated leadership and self-motivation; effective cross-functional collaborator who can fully represent manufacturing engineering on a distributed, multi-site product development team.\nWillingness to travel domestically and internationally (approximately 15-25%), including to St. Etienne, France and contract manufacturing sites.\n\nPreferred Qualifications\nFiber Optic Manufacturing: Direct experience with fiber handling, fusion splicing, connectorization, or optical assembly processes.\nFiber Connector Inspection: Familiarity with industry standard end-face pass/fail criteria.\nLaser Safety: Familiarity with Class 1M/3B laser safety practices in a manufacturing environment.\nContract Manufacturing: Experience preparing transfer packages and supporting CM launches, particularly in Asia or Europe.\n Handheld/Portable Products: Experience with ruggedized handheld instruments - enclosure assembly, overmold, battery integration, IP sealing, and drop/environmental qualification.\nExperience with modular or configurable product platforms where a common mainframe accepts multiple module configurations.\nERP/PLM system proficiency (SAP, Oracle, Windchill, Agile, or equivalent) for BOM, routing, and change management.\nSix Sigma Green/Black Belt, Lean certification, or equivalent continuous improvement credentials.\nUse of AI tools for process analysis, documentation development, or manufacturing data analysis.\nHow Success Is Measured\nManufacturing processes are defined, documented, and qualified in time to support pilot run and volume production launch.\nFirst-pass yield and cycle time meet or exceed targets established during NPI.\nProducts launch at or below target labor and material cost, with accurate routings and work content.\nTransfer packages are complete enough that receiving factories and CMs can execute the process without repeated clarification.\nManufacturing escapes and rework are minimal, and those that occur are driven to permanent root cause resolution.\nDFM feedback is delivered early enough in the design cycle to actually change the design.\nIf you have what it takes to push boundaries and seize opportunities, apply to join our team today.\nVIAVI Solutions is an equal opportunity and affirmative action employer - 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