DFA Engineer

Sierra Circuits is a Silicon Valley-based leader in printed circuit board manufacturing and assembly, specializing in high-quality, quick-turn and complex prototypes. With over 35 years of experience, Sierra provides a seamless, end-to-end PCB solution—from design and fabrication to assembly and testing—all under one roof at its state-of-the-art facilities in Sunnyvale, California. Sierra Circuits is committed to supporting engineers and designers through extensive educational resources. The company offers free online tools such as the Stackup Designer, Impedance Calculator, Material Selector, and BOM and DFM Checkers, along with technical blogs, webinars, design guides, and its SierraConnect community forum. Sierra Circuit serves all industries including aerospace, defense, medical, automotive, and telecommunications, building PCBs to the highest industry standards, and keeping innovation at the forefront of everything we do.

We are seeking an experienced DFA (Surface Mount Technology Design for Assembly) Engineer to join Sierra Circuit manufacturing team. In this role, you will work closely with design, process, and manufacturing teams to ensure the seamless assembly of printed circuit boards (PCBs) while optimizing product designs for manufacturability. You will be responsible for driving continuous improvements in SMT assembly processes, resolving technical challenges, and ensuring high-quality, cost-effective production.

RESPONSIBILITIES:

• Design for Assembly (ADFAE): Analyze PCB designs and provide feedback to improve manufacturability and efficiency during SMT production. Collaborate with design engineers to optimize component placements, solder joints, and assembly processes.
• SMT Process Development: Develop, optimize, and maintain SMT assembly processes, including stencil design, solder paste application, component placement, and reflow soldering, to ensure high-quality output.
• Manufacturing Support: Provide technical support and troubleshooting for SMT assembly lines. Collaborate with production teams to identify and resolve issues related to assembly defects, component fit, or solderability.
• Continuous Improvement: Lead initiatives for process improvements, yield enhancement, and cycle time reduction in SMT production. Implement best practices and drive Lean Manufacturing principles to improve overall efficiency.
• DFM Analysis: Conduct Design for Manufacturability (DFM) analysis on new and existing products, identifying potential design and process risks and offering solutions to minimize production disruptions and improve yields.
• Equipment Selection & Maintenance: Recommend SMT equipment upgrades or new purchases to enhance assembly capabilities. Ensure SMT machinery is properly calibrated and maintained.
• Develop Manufacturing Process Instructions (MPI’s) & Rework Instructions.
• Ensure that all proper documentation and data is available for all assembly jobs.
• Work with the Assembly Management Team to completely implement/monitor the Assembly Management System.
• Be available as back-up for walk-throughs, site audits, or any other requests from customers and partners.
• Quality Assurance: Collaborate with the quality engineering team to define inspection criteria, conduct root cause analysis of assembly defects, and implement corrective actions.
• Documentation & Reporting: Maintain detailed documentation of process parameters, technical issues, and solutions. Report findings and recommendations to relevant stakeholders.
• Cross-functional Collaboration: Work closely with cross-functional teams, including product design, process engineering, quality assurance, and supply chain to ensure product designs are optimized for manufacturability and meet production requirements.
• Work extended hours based on company needs and be available for after-hours emergency calls.
• Perform other duties as assigned.

QUALIFICATIONS:

• Education: Bachelor's degree in Mechanical Engineering, Electrical Engineering, or a related field. Equivalent experience will be considered.
• Experience: 2 – 5 + years of experience in SMT/DFA engineering in a high-volume manufacturing environment.
• Technical Skills:
  • Strong understanding of SMT assembly processes including stencil printing, pick-and-place, reflow soldering, and automated optical inspection (AOI).
  • Proficiency in Design for Manufacturability (DFM) and DFA principles.
  • Experience with SMT programming, equipment setup, and troubleshooting.
  • Familiarity with PCB design tools such as Altium Designer, Cadence Allegro, or similar.
  • Familiar with schematics, PCB fabrication drawings and electronic components that are mounted on electronic assemblies.
  • Able to evaluate Gerber files
• Problem-solving: Ability to diagnose and resolve complex assembly and design issues.
• Communication: Strong verbal and written communication skills for interfacing with multiple teams.
• Certifications: IPC-A-610 or J-STD-001 certifications are preferred.
• Excellent written and verbal sales communication skills.
• Ability to perform at the highest level in a fast-paced environment.
• Excellent oral and written communication skills.
• Exceptional multi-tasking, organizational skills, strong attention to detail and accuracy.
• Strong interpersonal skills and ability to work with all levels of management
• Self-motivator and a sense of ownership and urgency.
• Must be able to maintain confidentiality & professionalism at all times.
• Proficient in Microsoft Office using Excel, PowerPoint, and Word required.

Preferred Skills:

• Experience with Lean Manufacturing, Six Sigma, or other continuous improvement methodologies.
• Familiarity with high-reliability manufacturing industries such as automotive, aerospace, or medical devices.

PHYSICAL DEMANDS: The physical demands described here represent those that an employee must meet to perform the essential functions of this job successfully. While performing the duties of this job, the employee is regularly required to talk or hear. The employee must frequently stand, walk, and reach with hands and arms. The ability to lift 20 lbs., open filing cabinets, and bend, stand, or climb on step ladders as necessary.

ENVIRONMENT: Clean Manufacturing SMT Environment

CA salary range $85K - $120K per year.

What We Offer

• Full - Time, non-exempt position
• Excellent benefits package includes; Medical (HMO & PPO), Dental, Vision, Flexible Spending Accounts, Basic Life/ADD, Voluntary Benefits
• Vacation, sick and paid holidays