MANUFACTURING ENGINEER II

Manufacturing Engineer II

Broadata Communications, Inc. (BCI) – Torrance, CA
On-site

Company Overview
Broadata Communications, Inc. (BCI) is a privately held California-based corporation. BCI is a leading and innovative company specializing in the development of market-driven products for the transmission of digital multimedia (video, audio, and data) over fiber. Our clients are world leaders in their industries, spanning entertainment, broadcast, medical, professional audio/video, house of worship, education, government, military, and transportation sectors. We are ISO 13485 and ISO 9001 certified, with a strong commitment to quality, innovation, and continuous improvement.

Job Summary
We are looking for a talented and motivated individual as a Manufacturing Engineer II for Video and Audio systems. The right candidate will have the opportunity to be a contributor in ensuring the quality of our Pro AV products. The Manufacturing Engineer II will collaborate with Engineering, Quality, and Production Departments to ensure overall integrity and adherence to product specifications prior to product release and/or shipment. This position requires ownership of internal implementation of processes and procedures, training, and documentation creation.

This is an excellent opportunity for a detail-driven professional who thrives in a high-tech manufacturing environment and values teamwork, accountability, and continuous improvement. This critical, hands-on role is based in Torrance, CA. We offer a fast-paced, high impact and stimulating work environment with opportunities for professional growth and development within BCI. Veterans welcome!

This is a hands-on position. This is NOT a remote or hybrid position.

Key Responsibilities
Process Development & Validation

• Design, develop, and document manufacturing processes for cable assemblies, fiber optic components, PCBAs, and AV connectivity hardware.
• Lead Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) activities for new and modified manufacturing equipment and processes.
• Define and execute process validation protocols in compliance with ISO 13485 / Class I medical device.
• Conduct and document Measurement System Analysis (MSA) studies including Gage R&R, linearity, and bias assessments to confirm measurement system adequacy.

New Product Introduction (NPI)

• Drive NPI activities from concept through production readiness, including process development, tooling qualification, and manufacturing feasibility review.
• Conduct First Article Inspections (FAI) to verify that new and revised products meet engineering drawings, specifications, and customer requirements.
• Collaborate with Engineering and Quality to complete Design for Manufacturability (DFM) reviews during the product development phase.
• Develop and maintain Manufacturing Process Instructions (MPIs), work instructions, traveler documents, and assembly aids for new product launches.

Tooling & Equipment Qualification

• Define tooling requirements, evaluate vendor-supplied tooling, and manage qualification and ongoing maintenance of manufacturing tools and fixtures.
• Create and execute tool validation plans; maintain documentation in the QMS (QT9) in accordance with change control procedures.
• Coordinate equipment calibration programs with facilities and production, ensuring measuring and test equipment is maintained to applicable standards.

Supplier Quality & Visits

• Conduct on-site supplier visits and process audits to evaluate manufacturing capabilities, quality systems, and compliance with BCI and regulatory requirements.
• Participate in supplier qualification activities including capability assessments and initial sample evaluations.
• Work with the Supplier Quality team to resolve nonconformances, drive corrective actions (SCAR/CAPA), and support supplier development initiatives.

Lean Manufacturing & 5S

• Champion 5S (Sort, Set in Order, Shine, Standardize, Sustain) implementation and ongoing sustainment across manufacturing and warehouse areas.
• Conduct regular 5S audits, document findings, and drive corrective actions to maintain a safe, organized, and efficient work environment.
• Identify and eliminate the eight wastes through value stream mapping, time studies, and direct observation of production workflows.
• Develop standard work documentation and visual management systems to support sustained Lean practices on the production floor.
• Train and coach production staff on Lean principles, 5S expectations, and waste identification to build a culture of continuous improvement.

Kaizen & Continuous Improvement

• Plan, facilitate, and lead Kaizen events targeting cycle time reduction, yield improvement, scrap reduction, and ergonomic enhancement in manufacturing operations.
• Develop Kaizen event charters, coordinate cross-functional teams, and drive implementation of approved countermeasures through to closure.
• Track and report Kaizen event outcomes and post-event metrics to quantify savings and verify sustained improvement.
• Maintain a continuous improvement pipeline; identify opportunities through data analysis, gemba walks, and employee input.
• Foster a Kaizen mindset across the organization by engaging operators, technicians, and engineers in day-to-day problem solving and incremental improvement.

Six Sigma & Statistical Methods

• Apply Six Sigma DMAIC methodology to define, measure, analyze, improve, and control manufacturing processes with documented tollgate reviews.
• Support or lead Six Sigma projects targeting process variation reduction, defect elimination, and yield improvement aligned with business objectives.
• Mentor production and quality staff on basic Six Sigma concepts and statistical thinking.

Quality System & Documentation

• Author and maintain controlled documentation including SOPs, work instructions, validation protocols, and engineering change notices (ECNs) within the QMS.
• Support internal and external ISO 9001 and ISO 13485 audits; participate in management review activities.
• Support investigation and resolution of internal nonconformances and customer complaints through structured root cause analysis (8D, Fishbone, 5-Why).
• Other responsibilities as assigned.

Job responsibilities within our organization are dynamic. This may not be a complete list of duties. Other responsibilities and duties may be assigned by your supervisor or upper management.

Education & Experience

• B.S. in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or equivalent discipline.
• 3–5 years of hands-on manufacturing engineering experience in a regulated environment; medical device or FDA-regulated manufacturing strongly preferred.
• Demonstrated experience executing IQ/OQ/PQ validation protocols in compliance with ISO 13485 or 21 CFR Part 820.
• Hands-on experience with FAI processes and documentation (AS9102 or equivalent frameworks).
• Working knowledge of Measurement System Analysis (MSA/Gage R&R).
• Proven experience implementing 5S programs and sustaining Lean manufacturing practices on an active production floor.
• Six Sigma Green Belt certification required; Black Belt preferred. Demonstrated application of DMAIC on manufacturing improvement projects.
• Familiarity with cable and connector assembly manufacturing, fiber optic termination, or PCBA processes is a significant plus.
• Experience conducting supplier audits and on-site supplier quality visits.
• Proficiency with QMS software (QT9 or equivalent) and ERP systems (Sage 100, NetSuite or equivalent).
• Proficiency in MS Office and statistical analysis tools (Minitab or equivalent).
• Knowledge of IPC-A-610, IPC/WHMA-A-620, and related workmanship standards is preferred.

Skills & Abilities

• Strong organizational skills with high attention to detail and the ability to manage multiple concurrent projects.
• Excellent written and verbal communication skills; ability to author clear, concise technical documentation.
• Self-motivated and able to work with minimal supervision in a fast-paced, small-team environment.
• Collaborative team player with the ability to interface effectively across Engineering, Quality, Production, and Supply Chain.
• Willingness to travel domestically for supplier visits (estimated 10–20%).
• Demonstrated ability to self-learn and adapt quickly to new technologies and product domains.
• Proactive and capable of managing multiple priorities while adapting to changing business needs.
• Comfortable working in a fast-paced, cross-functional team environment, working extended hours (as needed).
• Proficient in Microsoft Excel and working knowledge of Microsoft Office Suite.

Physical Job Requirements
The employee in the position will be required to occasionally move throughout the facilities, including climbing stairs, when necessary. Occasional bending and reaching in an office environment, including opening and closing file cabinets drawers with light grasping. Type on a standard keyboard (laptop or desktop). Use standard computer display screens. Use standard push-button phones and must speak clearly and be understood by others. Sit or stand in a standard upright position for a minimum of one hour, but up to 12 hours a day. Be able to lift and carry weight unassisted not exceeding 50 lbs.

Compensation and Benefits

• Salary Range: $93,000 - $120,000 (based on experience and qualifications)
• Medical, vision and dental insurance
• 401(k) with company match (100% of the first 4% in eligible compensation)
• Flexible Spending Account
• 2 weeks paid vacation
• 1 Week sick pay
• 10 company holidays
• Group life insurance