Staff Engineer, Hardware Development Engineering

ESSENTIAL DUTIES AND RESPONSIBILITIES:

• Lead the development, optimization, and validation of HAMR ISA assembly processes, focusing on active alignment and laser soldering technologies.
• Collaborate with cross-functional teams, including design, quality, and manufacturing, to ensure seamless integration of new processes into production.
• Implement process improvements to enhance yield, reliability, and overall manufacturing efficiency.
• Serve as the subject matter expert in active alignment and laser soldering processes.
• Evaluate and integrate cutting-edge technologies to advance the HAMR ISA assembly process.
• Develop and maintain detailed process documentation, including work instructions, process flows, and control plans.
• Specify, procure, and validate equipment and tooling required for the HAMR ISA assembly process.
• Work closely with equipment vendors to ensure that machinery meets the necessary technical specifications and performance criteria.
• Troubleshoot and resolve equipment-related issues to minimize downtime and maintain high process capability.
• Implement robust process controls to ensure consistent product quality and adherence to specifications.
• Analyze process data to identify trends, root causes of defects, and opportunities for improvement.
• Lead efforts in corrective actions, root cause analysis, and continuous process improvement initiatives.
• Provide technical guidance and mentorship to junior engineers and technicians.
• Develop and deliver training programs for operators and technicians on HAMR ISA assembly processes.
• Foster a culture of safety, quality, and continuous improvement within the team.
• Lead and manage process development projects, including timeline creation, resource allocation, and progress tracking.
• Communicate project status, risks, and mitigation strategies to stakeholders and senior management.

REQUIRED

• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Materials Science, or a related field. A Master's degree is preferred.
• Minimum of 7 years of experience in process engineering, with a focus on precision assembly, active alignment, and laser soldering technologies.
• Proven track record in developing and scaling up manufacturing processes from R&D to high-volume production.

PREFERRED:

• Extensive experience (typically 7+ years) in designing, developing, and implementing manufacturing processes, particularly in high-precision environments such as electronics, semiconductors, or advanced materials.
• Proven ability to optimize manufacturing processes for increased efficiency, yield, and cost-effectiveness, using methodologies such as Lean Manufacturing, Six Sigma, or other continuous improvement techniques.
• Deep expertise in specific technologies relevant to the role. For instance, in the context of HAMR ISA assembly, experience with active alignment techniques, laser soldering, and precision assembly is crucial.
• Strong background in selecting and validating materials, tooling, and equipment. This includes hands-on experience with advanced manufacturing equipment, such as laser systems, robotic alignment tools, and other precision machinery.
• Extensive experience in implementing and maintaining quality control systems, including Statistical Process Control (SPC) and other advanced quality assurance methodologies.
• Demonstrated ability to conduct thorough root cause analysis and implement corrective actions to resolve process-related issues, minimizing defects and improving overall product quality.
• Expertise in collecting, analyzing, and interpreting process data to drive improvements. This includes experience with data analysis tools and techniques used to monitor process performance and identify areas for optimization.
• Strong problem-solving skills, with a track record of using data-driven approaches to identify inefficiencies, troubleshoot issues, and enhance process reliability.
• Significant experience managing process development projects, from initial concept through to production scale-up. This includes creating project plans, allocating resources, managing budgets, and ensuring timely delivery.
• Experience working in cross-functional teams, coordinating with departments such as design, quality, R&D, and production to ensure that process changes are implemented smoothly and effectively.
• In-depth understanding of industry standards and regulatory requirements, with experience ensuring that processes meet necessary certifications (e.g., ISO, FDA, or other relevant industry standards).
• Experience in developing processes that not only meet performance criteria but also comply with environmental, safety, and regulatory guidelines.
• Demonstrated experience in introducing new technologies or innovative methods into existing manufacturing processes, leading to significant improvements in efficiency, quality, or cost reduction
• Certified experience in Lean Manufacturing, Six Sigma (often Black Belt level), or other continuous improvement frameworks, with a proven record of driving measurable improvements.
• Experience leading and mentoring engineering teams, including training and developing junior engineers and technicians. This also includes fostering a culture of safety, quality, and continuous improvement within the team.
• Strong communication skills, with a proven ability to convey complex technical information clearly and effectively to both technical and non-technical stakeholders, including creating process documentation and delivering presentations.
• Experience in developing and enforcing safety protocols within manufacturing environments. This includes ensuring that processes are safe for operators and compliant with environmental regulations.
• Experience in implementing processes that minimize environmental impact, including waste reduction, energy efficiency, and compliance with environmental laws.
• Extensive experience in managing relationships with equipment vendors and suppliers, including specifying requirements, negotiating contracts, and ensuring that equipment meets all necessary specifications.
• Proven track record in the validation of equipment and tools, ensuring they perform to the required standards within the manufacturing process.

SKILLS:

• In-depth knowledge of HAMR technology and ISA assembly processes.
• Proficiency in using advanced manufacturing equipment, including laser systems and precision alignment tools.
• Strong analytical skills with experience in statistical process control (SPC) and data analysis.
• Excellent problem-solving abilities, with a focus on root cause analysis and corrective action implementation.
• Ability to work independently and as part of a cross-functional team in a fast-paced environment.
• Strong communication and presentation skills in English.

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