Staff, Manufacturing Engineer

Summary:

Develops, implements and maintains methods, operation sequence and processes in the manufacture or fabrication of parts, components, sub-assemblies and final assemblies. Interfaces with design engineering in coordinating the release of new products. Estimates manufacturing cost, determines time standards, and makes recommendations for tooling and process requirements of new or existing product lines. Maintains records and reporting systems for coordination of manufacturing operations.

Duties & Responsibilities:

Overview

On site support for CM (Thailand) and interface to remote teams at the NPI sites. Provide expertise on the product functionality and triage issues escalated by the CM

• Ensure product yields meet the specified targets
• Implement changes via ECO/MCO and Deviation in agreement with the Product Engineers in the NPI sites.
• Triage product issues in production and support the CM debug technicians to analyze failures impacting cycle times and yields.
• Support NPI organization for new product releases - prototype and pilot builds. Train CM team on new product processes for assembly and ensure all Work Instructions are in place.
• Evaluate existing manufacturing processes and work with both internal and external 3rd party
• Support implementation of formal continuous improvement activities within optical product line at the CM.
• This position may require up to 20% international travel

Role and Responsibilities

Assembly

• Develops implements and maintains methods, operation sequence and processes in the manufacture or fabrication of PCBAs, sub-assemblies and final assemblies.
• Interfaces with Ops NPI PM and Manufacturing Engineering in coordinating the release of new products. Estimates manufacturing cost, determines time standards and makes recommendations for tooling and process requirements of new or existing product lines.
• Maintains work instructions and reporting systems for coordination of manufacturing operations.

Equipment

• Evaluates, selects and orders equipment that is most appropriate and cost effective for the manufacture of Viavi products.
• Oversees the installation, modification, upgrade and maintenance of manufacturing equipment.
• Maintains current records on equipment manufacturers’ technical notices, upgrades and safety issues. Studies equipment performance and reliability.
• Establishes programs and solutions for increasing uptime and for equipment problems that affect the manufacturing process.
• Provides technical support to the manufacturing equipment repair and process engineering organizations.

Process

• Provides technical and sustaining engineering support in manufacturing.
• Recommends and implements equipment and process modifications to improve
• production efficiencies, manufacturing techniques and production yields for existing products.
• Develops and conducts statistical analysis such as Design of Experiments (DOE) and Statistical Process Control (SPC) targeting physical cause of failure for yield loss and improving quality.
• Investigate complex process issues to root cause (yield, component, rework, repair bone pile). Drive corrective actions.
• Partner with the Viavi Product Engineers and the CM to drive process improvements across all Viavi boards and products to achieve reduced cycle times and cost reductions
• Partner with the CM and Viavi Product Engineers to produce effective work instructions for board and box production
• Manage Engineering Change Order execution at the CM to achieve order objectives.
• Manage Stop Ship / Stop Build execution at the CM to protect the customer and drive to quick resolution of CM related issues

New Product Introduction

• Lead the 1st tier support of Contract Manufacturer process issues related to Viavi PCBA or box during pilot and proto builds
• Carefully monitor prototype and pilot builds during development of new products (NPI). Collect yield, DFX, etc. Prove out methods and work instructions.
• Define manufacturing plans for new boards and boxes
• Document and train the CM technicians on specific board and box troubleshooting techniques.
• Audit manufacturing readiness for prototype and pilot builds.

Production Test Support

• First-line troubleshooting for production issues occurring at PCBA or instrument-level test
• Monitor CM performance with respect to:
  • Capacity planning (Duplicate test stands if necessary)
  • Equipment calibration
  • Test stand preventive maintenance
• Engineering change implementation
• Periodic verification of test system performance
• Write and execute production validation plans for proposed product or process changes (CPMEs and dry runs)
• Escalate issues requiring test stand design changes to Test Development Engineers

Qualifications and Experience

• BS / MS degree or equivalent in Electrical or Manufacturing Engineering is a must
• 8+ years of relevant experience in a technology driven industry -optical and electromechanical products (motor driven assemblies, lenses, cameras, lasers, and optical fiber).
• Demonstrated ability to influence and participate on cross functional teams and 3rd party CM partners
• Proven experience debugging and supporting optical and electromechanical products.
• Good understanding in optical principles
• Knowledge of optical test equipment for use on debugging of products - such as optical power source, optical power meter, variable optical attenuator, etc.
• Proven experience of laser, optical and handling fibers - splicing, routing, cleaning, connectors and switching.
• Experience of alignment processes - lenses, fibers, mechanicals, and epoxy setting.
• Proven contract manufacturing support experience both at a box build level and at surface mount levels
• Ability to work with a global organization and remote teams

Thai and English-speaking skills mandatory.

Pre-Requisites / Skills / Experience Requirements: