Staff NPI Engineer (PCBA)

Overview

Lead PCBA NPI, ensuring manufacturability, testing, and CM coordination for production.

Key Responsibilities

• npi lead
• smt qualification
• test strategy
• design review
• eco management
• second sourcing

Tasks

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

Requirements

• six sigma
• dfm/dft
• pcba
• smt
• npi
• automation

What You Bring

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

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About Span

-Founded with a vision to revolutionize energy consumption, Span integrates advanced technology with everyday living. -The company develops smart energy management systems, optimizing energy use for residential and commercial spaces. -Span's solutions focus on reducing energy costs, improving grid management, and promoting sustainable energy practices. -With a blend of hardware and software, Span enables users to monitor and control their energy usage in real-time. -The company has made significant strides in the energy tech industry, gaining recognition for its cutting-edge innovations. -Typical projects include the installation of smart panels, electric vehicle chargers, and energy storage solutions. -Span's commitment to energy efficiency positions it as a leader in shaping the future of smart home and commercial energy solutions.

Sector Specialisms