Printed Circuit Assembly (PCA) Manufacturing Engineer - Defense Electronics

Summary:

We are seeking a Manufacturing Engineer specializing in Printed Circuit Assembly (PCA) to support the production of advanced defense electronics, including software-defined radios, RF/microwave assemblies, and complex circuit card assemblies.

Description:

This role will focus on process development, production support, yield improvement, and continuous improvement in a low-to-medium volume, high-mix environment. The Manufacturing Engineer will act as the technical liaison between design engineering, operations, quality, and supply chain to ensure robust, repeatable, and compliant manufacturing processes for PCA builds.

Key Responsibilities:

• Develop, implement, and optimize manufacturing processes for printed circuit assembly (through-hole, SMT, and mixed-technology boards).
• Provide technical support to in-house and contract manufacturing production, test, and rework personnel, troubleshooting build issues and implementing corrective actions.
• Collaborate with design engineering and supply chain to ensure Design for Manufacturability (DFM) and Design for Testability (DFT) on new PCA designs.
• Author and maintain manufacturing process documentation (work instructions, travelers, process flows, rework guides).
• Drive root cause and corrective action (RCCA) efforts for assembly nonconformances and yield issues.
• Define and implement process controls for soldering, reflow, wave solder, conformal coating, underfill, and rework/repair
• Select tools, fixtures, soldering materials, and consumables appropriate for defense/aerospace electronics
• Support and qualify new equipment, tooling, and process technologies.
• Work with suppliers (PCB and Assembly) to identify and implement process improvements.
• Work with supply chain and suppliers to address component quality issues and support alternate part qualifications.
• Ensure compliance with IPC-A-610, J-STD-001, IPC-7711/7721, and customer/DoD quality standards.
• Provide training and technical guidance to production operators and technicians.
• Identify and lead continuous improvement projects to reduce cycle time, improve yields, and enhance quality.

Qualifications:

Required:

• Bachelor s degree in Manufacturing Engineering, Electrical Engineering, Mechanical Engineering, or related technical field.
• 3+ years of experience in electronics manufacturing, with emphasis on PCA assembly.
• Strong knowledge of SMT processes, through-hole soldering, and mixed-technology assemblies.
• Familiarity with defense/aerospace quality standards and documentation requirements.
• Experience with root cause analysis and corrective action (8D, Ishikawa, FMEA, etc.).
• Proficiency with CAD/CAM tools, Gerber files, and assembly drawings.
• Knowledge of IPC standards (IPC-A-610, J-STD-001, IPC-7711/7721, IPC-2221).

Preferred:

• Experience in low volume, high-mix defense electronics
• Familiarity with ERP/MRP systems (e.g., Costpoint) for work order tracking and production support.
• Understanding of RF/microwave PCA design constraints (controlled impedance, grounding, shielding).
• Experience introducing new PCA products (NPI) into production.
• Lean Six Sigma or similar continuous improvement training/certification.

Work Environment:

• Manufacturing floor and lab environment with frequent interaction with technicians, assemblers, inspectors, and engineering.
• Hands-on involvement with soldering, rework, and assembly process verification.

Benefits:

• Startup Environment
• Competitive Salaries
• Health Insurance
• 401K Matching
• Bonuses for superior performance