Process Development Engineer

Manufacturing & Process Development Engineer IIAt TE, you will unleash your potential working with people from diverse backgrounds and industries to create a safer, sustainable and more connected world.Job Overview: Manufacturing Process Development Engineer – Optical Connector Termination Systems, Digital Data Networks (DDN) Business Unit | TE ConnectivityThe Opportunity: Join TE Connectivity's industry-leading Passive Optics organization as a Manufacturing Process Development Engineer and drive manufacturing excellence in optical connector termination processes. You'll tackle complex manufacturing challenges in high-precision fiber optic termination, working with advanced production technologies and lean manufacturing principles to optimize both internal operations and external contract manufacturing partnerships that enable the world's most demanding optical connectivity applications.Why This Role Matters: As optical interconnect demand accelerates across AI, hyperscale computing, and 5G infrastructure, manufacturing excellence in fiber optic termination has become mission-critical. You'll be at the forefront of developing scalable, robust manufacturing processes that directly enable TE's competitive advantage while ensuring world-class quality and cost performance in optical connectivity manufacturing.Please note: operations are currently based at a temporary site in Webster, NY. The team will transition to a permanent Rochester location (near RIC) upon completion.Job RequirementsWhat You'll Engineer:Manufacturing Process Development & OptimizationDesign and optimize end-to-end optical connector manufacturing processes, including fiber prep, termination, polishing, and testing.Develop process flows, work instructions, and manufacturing specifications for single-mode and multi-mode optical assemblies.Lead DFM reviews to ensure new designs meet volume, quality, yield, and cost goals.Drive PFMEA activities to identify risks and implement preventive controls.Create complete production documentation (process specs, control plans, WI, quality procedures).Tooling, Equipment, and Process Qualification:Prepare and qualify tools, fixtures, and equipment for precision optical termination.Lead qualification builds and validation runs (LVM, sample runs) to confirm capability and statistical control.Coordinate qualification documentation, reviews, and approvals.Manage pilot runs for new products, resolving engineering issues and validating process capability.Establish and track key manufacturing metrics (Cpk, yield, cycle time).Technical Problem Solving & Continuous Improvement:Lead FACA/root-cause investigations for manufacturing issues.Implement continuous improvement using TEOA tools for cost, yield, and cycle-time optimization.Run Kaizen events to eliminate waste, improve throughput, and reduce changeovers.Enhance equipment reliability, process durability, and spare-parts efficiency.Improve safety via machine guarding, control reliability, and operator protection initiatives.Technician Development & Training:Train and mentor operators and technicians in optical termination methods and quality practices.Develop and deliver technical training on fiber handling, termination, inspection, and troubleshooting.Implement competency assessments and certification programs.Build mentorship programs to support skill development and knowledge transfer.Operational Excellence & Manufacturing Systems:Update routing, cycle times, and parameters after process changes.Optimize material flow, workspace layout, and personnel movement to reduce waste.Support CapEx/OpEx decisions through cost, capability, and vendor analysis.Integrate test systems, automation equipment, and MES for smooth production operations.Future Technology & Innovation:Develop technology roadmaps for next-generation optical connector manufacturing.Innovate new processes for advanced connectors (expanded beam, ganged ferrules, high-density systems).Define automation strategies including robotic handling, automated polishing, and AI-based inspection.Drive Industry 4.0 initiatives using IoT, predictive maintenance, and manufacturing analytics.What Your Background Should Look LikeEssential Qualifications:Education: BS in Manufacturing, Mechanical, Industrial Engineering, or related field.Experience: 2–5 years in manufacturing process development, ideally in precision assembly, fiber optics, or electronics.Technical Skills: Hands-on experience with optical connector termination, fiber handling, precision processes, and SPC.Process Knowledge: Strong foundation in Lean, Six Sigma, and continuous improvement.Core Technical Competencies:Optical Manufacturing: Proficiency in fiber cleaving, polishing, inspection, and optical testing with tight tolerance control.Manufacturing Systems: Experience with precision equipment, automated assembly, process validation, and equipment qualification.Quality Engineering: Skilled with PFMEA, SPC, control plans, MSA, and quality assurance tools.Process Documentation: Able to create clear process specs, work instructions, training content, and qualification protocols.Data & Statistics: Experience with statistical tools (e.g., Minitab, JMP) and capability analysis.Specialized Knowledge:Fiber Optics: Expertise in single-mode/multi-mode handling, end-face prep, polishing, and testing.Precision Assembly: Strong understanding of high-precision mechanical assembly, alignment, and dimensional control.Supplier/CM Management: Experience with tech transfers, supplier qualification, and contract manufacturing.Automation & Robotics: Familiarity with robotics, vision systems, automated test, and process control systems.Lean & Six Sigma: Green Belt or higher; experienced in Kaizen and waste-reduction methods.Process Control: Proven ability in SPC implementation, MSA, and capability studies.Professional Skills:Problem Solving: Strong analytical and root-cause-analysis abilities.Project Management: Skilled in managing cross-functional projects and meeting aggressive deadlines.Communication: Able to present technical concepts clearly across all organizational levels.Leadership: Experience leading FACA efforts, improvement initiatives, and mentoring technical staff.Preferred Qualifications:Education: MS in Manufacturing/Industrial Engineering or related field.Industry Experience: Background in telecom, data center, automotive, or aerospace precision manufacturing.Certifications: Six Sigma Black Belt, Lean certification, PE license, or CMfgE.Software: Experience with simulation tools, CAD, MES, and ERP systems.Standards Knowledge: Familiarity with ISO 9001, TS 16949, and optical standards (IEC, TIA/EIA).Competencies Values: Integrity, Accountability, Inclusion, Innovation, TeamworkAbout TE Connectivity:TE Connectivity plc (NYSE: TEL) is a global industrial technology leader creating a safer, sustainable, productive, and connected future. As a trusted innovation partner, our broad range of connectivity and sensor solutions enable the distribution of power, signal and data to advance next-generation transportation, energy networks, automated factories, data centers enabling artificial intelligence, and more. Our more than 90,000 employees, including 10,000 engineers, work alongside customers in approximately 130 countries. In a world that is racing ahead, TE ensures that EVERY CONNECTION COUNTS. Learn more at Competitive base salary commensurate with experience: $82,000 – $123,000 (subject to change dependent on physical location)• Posted salary ranges are made in good faith. TE Connectivity reserves the right to adjust ranges depending on the experience/qualification of the selected candidate as well as internal and external equity.• Total Compensation = Base Salary + Incentive(s) + BenefitsBenefits:• A comprehensive benefits package including health insurance, 401(k), disability, life insurance, employee stock purchase plan, paid time off and voluntary benefits.EOE, Including Disability/VetsImportant Notice Regarding Recruitment Fraud: