Process Engineering Full Time NEW

SME – Washing & Coating Process is responsible for overseeing, optimizing & continuously improving processes to ensure on-time manufacturing with high quality of all ISP Products. The Washing & Coating Line Expert owns end-to-end process capability, throughput, and quality for PCB assembly cleaning post SMT and conformal coating operations.

This role develops, validates, and continually improves cleaning and coating processes to meet reliability & yield requirements across product lifecycles, ensuring robust control over chemical systems, equipment, masking strategy, film build, and cure profiles.

Also role is accountable for cost saving while building strong cross functional alignment with NPI & TD, equipment, quality and customer teams.

Key Responsibilities

• Technology & Process Setup
• Define & maintain process windows for inline / batch PCB cleaning (DI water , aqueous , semi aqueous , solvent) and conformal coating (spray , selective , dip , brush).
• Define and maintain all process windows, control plans & CTQ across all products.
• Monitor critical parameters ( Spray Pressure , Temp. , Conveyor Speed , Chemical Concentration, Rinse Quality & resistivity)
• Setup & optimize selective and spray coating machines.
• Programming of coating paths & Control Coating Thickness (DFT measurement).
• Operate and maintain ( Inline PCB washers , Ultrasonic cleaning machines , UV curing ovens & Thermal curing ovens )
• Ensure masking accuracy and proper curing (UV/Thermal). Also management of viscosity control.
• Conduct DOE & Process validation for new products and materials.
• Establish and maintain Golden Board and Golden Sample libraries for cleaning and coating validation.
• Optimize cure profiles (thermal/UV/moisture) and coating thickness as per design & environment class.
• New Model Readiness
• Develop & Maintain Process documentation, WIs & SOPs (Washing & Coating Line)
• All new models trail pre-readiness (EVT/ DVT / PVT) , new model trail activities including trial builds & process validation.
• Partner with NPI, TDG to ensure DFMEA and PFMEA of Washing & Coating Processes of new coming products to ensure cleanability and coatability (Component spacing , keepouts , edge clearance , standoff).

Also ensure PCBA cleanliness risk assessments during FMEA.

• Ensure smooth technology transfer from development to production.
• Own ramp-up metrics: yield learning curve, cycle time, scrap reduction.
• Quality Excellence
• Accountable for first pass yield, final yield and field reliability.
• Troubleshoot residue , white stains , flux contamination and drying issues.
• Lead root cause analysis for yield excursions using Yield Trends ,FMEA, DOE and failure analysis.
• Monitor production yield , defect rates , cycle time and implement corrective / preventive actions.
• Collaborate with Quality , NPI & Customer to resolve manufacturing & Quality issues such as (peeling , bubbles ,delamination)
• Partner with Quality team to address customer returns, audits and escalations.
• Conduct coating inspection under UV Light.
• Perform thickness measurement (wet film gauge / micrometer)
• Conduct environmental reliability tests ( temp. cycling , humidity Testing , salt spray testing )
• Operational Excellence & Cost Optimization
• Own cost of ownership and productivity improvement initiatives.
• Drive Cycle time and line balancing improvements.
• Lead process development , validation & continuous improvement initiatives ( Kaizen , Poka yoke , Lean Manufacturing )
• To ensure Proper line setup , programming , Program version management.
• To ensure compliance with ESD , Safety& IPC standards.
• Analyze process data , SPC reports to identify trends & improvement opportunities.
• Ensure EHS compliance for chemical handling.
• Maintain MSDS documentation.
• Customer & Stakeholder Engagement
• Will be technical team member for customer reviews, technology discussions and risk mitigation plans on PCBA Washing & Coating topics.
• Support customer audits and regulatory compliance.

Key Deliverables & KPI

• First Pass Yield & Process capability (Cp/Cpk)
• Coating Defect Rate (%)
• Productivity Improvement
• Cost Optimization
• Customer satisfaction and audit outcomes.

Education Qualifications

• Bachelor in related Engineering Discipline (Electronics/Mechanical/ Chemical)
• 8-10 years’ hands on experience in SMT industry in a similar role (Washing & Conformal Coating Process)
• Experience in high volume manufacturing environment.
• Hands on experience with selective coating machines ( Nordson / Asymtek etc )
• Proficiency in root cause analysis & problem solving tools ( 8D , 5 why , DOE )
• Familiar with Lean manufacturing.
• Strong Knowledge of ( SMT assembly processes , IPC standards , conformal coating materials , PCB cleaning chemistry)