PCBA Process Engineer

PCBA Process Engineer

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world. A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment. If you are excited about a role but don't meet every bullet point, we encourage you to apply and join us to create the extraordinary.

Job Summary

The PCBA (Printed Circuit Board Assembly) Process Engineer is responsible for developing, optimizing, and sustaining manufacturing processes for electronic assemblies. This role focuses on ensuring high-quality, cost-effective, and scalable PCBA production through process design, equipment optimization, defect reduction, and continuous improvement across SMT and through-hole operations.

Key Responsibilities

• Develop, validate, and improve SMT assembly processes including solder paste printing, pick-and-place, reflow.
• Establish and maintain process parameters, work instructions, control plans, and standard operating procedures.
• Lead process characterization (DOE, capability studies) to ensure robust and repeatable manufacturing performance.
• Provide day-to-day engineering support to production lines to resolve yield, quality, equipment, or throughput issues.
• Analyze process data and defect trends using SPC and root-cause analysis tools to drive corrective actions.
• Support ramp-up of new products from NPI through full production.
• Drive defect reduction initiatives targeting solder defects, component damage, alignment issues, and functional failures.
• Support PFMEA creation and maintenance for PCBA processes.
• Collaborate with Quality Engineering on customer complaints, audits, and corrective/preventive actions.
• Define equipment requirements and support selection, qualification, and deployment of SMT and PCBA manufacturing equipment.
• Work with maintenance and vendors to optimize equipment performance, uptime, and reliability.
• Specify and validate fixtures, stencils, solder profiles, and tooling.
• Collaborate with Design Engineering on DFM/DFA reviews to improve manufacturability and testability.
• Support Supply Chain with material evaluations, alternate components, and supplier process readiness.
• Train operators and technicians on new processes, equipment, and best practices.
• Maintain accurate process documentation, change control, and traceability records.
• Ensure compliance with IPC standards (e.g., IPC-A-610, J-STD-001) and internal quality requirements.

Required Qualifications

• BS Mechanical Engineering, Electrical Engineering or Manufacturing Engineering or equivalent experience
• 5+ years of experience in PCBA or electronics manufacturing.
• Strong understanding of SMT
• Hands-on experience with reflow profiling, solder paste printing, and defect analysis.
• Familiarity with IPC standards and electronic assembly quality requirements.
• Knowledge of automated equipment systems and tools - robotic, vision, material handling, Conveyors, PLC, HMI, Pick-Place-Pack, Inspection/Test
• Experience using data-driven problem-solving tools (DOE, SPC, 8D, Ishikawa).
• Knowledge of AOI, SPI, X-ray inspection, and functional test integration.

Preferred Qualifications

• 2 years' experience working with manufacturing of medical devices
• Industrial/Manufacturing Engineering experience working in high-volume assembly processes.
• Excellent verbal, written and critical thinking skill
• Experience with high speed low mix or regulated manufacturing environments.
• Familiarity with lean manufacturing and continuous improvement methodologies (Six Sigma, Kaizen).
• Experience supporting automation or Industry 4.0 initiatives.

Key Skills & Competencies

• Strong analytical and troubleshooting skills.
• Ability to manage multiple projects simultaneously in a fast-paced environment.
• Excellent communication skills for cross-functional teamwork.
• Detail-oriented with a focus on process discipline and standardization.

Work Environment

• Manufacturing floor and office environment.
• May require occasional travel to suppliers or contract manufacturers.
• Hands-on involvement with production equipment and processes.

What you'll receive for the great work you provide:

• Full range of medical, dental, and vision plans
• Life Insurance
• Short-term and Long-term Disability
• Matching 401(k) Contributions
• Vacation and Paid Sick Time
• Tuition Reimbursement

Pay Range (Applicable to Illinois)$99,900.00 USD - $137,400.00 USD Annual

Job Category

Production Engineering

Is Sponsorship Available?

NoFlex is an Equal Opportunity Employer and employment selection decisions are based on merit, qualifications, and abilities. We do not discriminate based on: age, race, religion, color, sex, national origin, marital status, sexual orientation, gender identity, veteran status, disability, pregnancy status, or any other status protected by law. We're happy to provide reasonable accommodations to those with a disability for assistance in the application process. Please email View email address on click.appcast.io and we'll discuss your specific situation and next steps (NOTE: this email does not accept or consider resumes or applications. This is only for disability assistance. To be considered for a position at Flex, you must complete the application process first).