SPAN

Staff NPI Engineer, PCBA

SPAN

full-time

Posted on:

Origin:  • 🇺🇸 United States • California

Visit company website
✨ AI Apply
Apply

Salary

💰 $120,000 - $160,000 per year

Job Level

Lead

Tech Stack

AssemblyRay

About the role

  • Lead the NPI process for PCBAs and electronics subassemblies, from prototype to high-volume manufacturing
  • Apply DFx principles (DFM, DFT, DFQ, DFR, DFC) to electronic designs to ensure robust manufacturability, test coverage, and quality
  • Partner with design engineers to review Gerbers/ODB++, schematics, and layouts for manufacturability and testability
  • Define and implement PCBA test strategy (ICT, FCT, boundary scan, functional test fixtures) in collaboration with hardware and test engineering
  • Drive SMT line qualifications, reflow profile validation, selective soldering, AOI/X-ray coverage, conformal coating and other PCBA processes
  • Investigate and resolve issues with new designs and prototypes through assembly, testing, and system integration
  • Own technical deliverables for CM onboarding, including process requirements, yield targets, test coverage, and quality control plans
  • Identify and qualify quick-turn vendors to support prototype and early build activities
  • Develop and implement second-sourcing strategies to drive cost reduction and ensure supply continuity
  • Create, review, and submit engineering change orders (ECOs) to release design and process changes
  • Evaluate technical readiness before release and conduct Technical Readiness (TR) reviews with cross-functional teams
  • Conduct BOM risk assessment, component testing, second sourcing, and manage Product Change Notifications (PCN) and qualifications
  • Improve manufacturing operations to enhance efficiency, consistency, and cost-effectiveness while ensuring high product quality
  • Generate and maintain manufacturing documentation (BOMs, ECOs, test procedures, visual aids, specifications)
  • Drive value engineering and cost reduction activities to optimize product lifecycle costs
  • Travel to CM sites (~25–40%) for builds, process qualifications, and troubleshooting

Requirements

  • BS or MS in Electrical Engineering, Electronics Engineering, Manufacturing Engineering, or equivalent discipline
  • 8+ years of experience in NPI and PCBA manufacturing engineering
  • Deep knowledge of SMT processes, reflow soldering, wave/selective soldering, conformal coating, and in-circuit/functional test methods
  • Hands-on experience with DFM/DFT tools, Gerber/ODB++ analysis, and PCBA CAD data review
  • Proficiency in DFx principles: DFM, DFT, DFQ, DFR, DFC
  • Strong knowledge of complex system-level debugging and root cause analysis
  • Expertise in ECO, BOM, and deviation processes
  • Knowledge of manufacturing, test, quality, and reliability best practices
  • Ability to establish technical direction through the investigation and evaluation of new manufacturing technologies
  • Strong working knowledge of industry manufacturing standards such as IPC and JEDEC
  • Experience with process development, characterization, and pFMEA
  • Ability to travel to contract manufacturer (CM) sites ~25–40%
  • Bonus: Experience with automation technologies and robotics in manufacturing processes
  • Bonus: Six Sigma Black Belt, or Lean Manufacturing certification
  • Bonus: Proven track record driving PCBA NPI strategy at a fast-growing hardware company