Process Optimization Engineer

Key Responsibilities 1. Process Monitoring and Improvement: • Monitor production processes and analyze data to identify trends, process inefficiencies, and quality issues. • Develop and implement corrective and preventive actions (CAPA) to address process deficiencies and reduce defect rates. • Conduct process capability studies (Cp, Cpk) to ensure process stability and capability. • Drive continuous improvement initiatives using tools such as Lean Manufacturing, Six Sigma, or DMAIC. 2. Root Cause Analysis and Problem-Solving: • Lead root cause analysis (RCA) for process-related quality issues using tools like 5 Whys, Ishikawa diagrams, or 8D reports. • Implement and monitor the effectiveness of corrective actions to prevent recurrence. • Collaborate with production, engineering, and quality teams to resolve process-related problems quickly. 3. Process Validation and Qualification: • Oversee process validation activities, including Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ). • Validate new equipment, tools, and processes to ensure they meet quality and production requirements. • Support new product introduction (NPI) by establishing quality requirements and validating processes for production readiness. 4. Quality Assurance and Compliance: • Ensure compliance with quality standards such as ISO 9001, ISO 14001, and customer-specific requirements. • Conduct internal audits and support external audits to ensure adherence to regulatory and quality standards. • Develop and maintain process control plans, work instructions, and quality procedures 5. Data Analysis and Reporting: • Utilize statistical tools such as SPC (Statistical Process Control) to monitor process performance and identify improvement opportunities. • Prepare and present regular reports on process quality metrics, including yield, defect rates, and scrap rates. • Drive decision-making based on data analysis and fact-based recommendations. 6. Customer Interaction: • Serve as the technical liaison for customer quality concerns related to process issues. • Support customer audits, provide necessary documentation, and implement agreed corrective actions. • Communicate effectively with customers on quality performance and improvement plans. 7. Supplier Quality Collaboration: • Work with the supplier quality team to address incoming material defects and ensure process compatibility with supplier-provided materials. • Provide feedback and improvement suggestions to suppliers based on process requirements. 8. Training and Support: • Train production staff and operators on quality standards, processes, and inspection techniques. • Ensure adherence to standard operating procedures (SOPs) and quality guidelines. Key Requirements: 1. Education and Experience: • Education: o Bachelor’s degree in Mechanical, Electronics, Electrical, or Industrial Engineering, or a related field. • Experience: o 3-7 years of experience in process quality engineering or a similar role in an EMS or manufacturing environment. o Proven experience in handling quality issues for SMT (Surface Mount Technology), PCB assembly, and electronic products. o Familiarity with validation processes and advanced quality planning. 2. Skills and Competencies: • Technical Skills: o Proficiency in quality tools and techniques such as SPC, FMEA, DOE, CAPA, and root cause analysis. o Hands-on experience with statistical analysis tools like Minitab or JMP. o Strong understanding of process validation and control methods. • Soft Skills: o Strong analytical and problem-solving abilities. o Excellent communication and interpersonal skills to collaborate effectively across departments. o Detail-oriented with the ability to manage multiple priorities in a fast-paced environment. 3. Certifications (Preferred): • Six Sigma Green Belt or Black Belt certification. • Certified Quality Engineer (CQE) or equivalent. • ISO 9001 Lead Auditor or similar certification.