NPI Process Engineer

Company Description

XP Power is a major supplier of critical power conversion technology to the medical, technology, industrial and defense markets. We are a fast-growing company listed on the London Stock Exchange. We are looking for self-motivated professional who thrive in dynamic environments. We are proud of and committed to our culture that values Customer Focus, Flexibility, Knowledge, Speed and Integrity. Joining our team means you will work in a high performing global company where employees collaborate and strive for excellence.

Job Description

Position Summary

The Process Engineer is responsible for developing, implementing, and continuously improving manufacturing processes. This position supports New Product Introduction (NPI), production readiness, process optimization, and manufacturing issue resolution within a power-supply manufacturing environment.

Key Responsibilities

• Review and approve manufacturing work instructions in the eMOI system.
• Develop and optimize manufacturing processes for new and existing products.
• Support NPI activities from prototype and pilot builds through mass-production ramp-up.
• Perform DFM and DFA reviews for PCBAs, mechanical assemblies, and final product assemblies.
• Review drawings, BOMs, specifications, Gerber data, and engineering changes for manufacturability.
• Identify manufacturing risks and recommend improvements for quality, productivity, yield, assembly efficiency, and automation readiness.
• Ensure that approved processes, procedures, machine programs, visual aids, tooling, fixtures, equipment, materials, and trained personnel are available according to the production schedule.
• Prepare and maintain:
• Work instructions and visual aids
• Process flow diagrams
• PFMEA and Control Plans
• Process parameters and acceptance criteria
• Tooling and equipment requirements
• Production-readiness checklists
• Process validation and qualification reports
• Conduct operation and time studies to establish standardized work, cycle time, UPH, manpower requirements, and line balancing.
• Support line setup, equipment installation, machine programming, process qualification, and capacity verification.
• Train and certify production personnel on new products, processes, equipment, work instructions, and quality requirements.
• Identify and implement continuous-improvement projects to improve quality, productivity, yield, OEE, and delivery while reducing downtime, defects, scrap, rework, and manufacturing cost.
• Apply structured problem-solving methods such as 4M, 5 Why, Fishbone Diagram, Pareto Analysis, PDCA, DMAIC, and 8D.
• Conduct root-cause analysis and implement corrective and preventive actions for production and process issues.
• Work with Production, Quality, R&D, NPI, Equipment, Test Engineering, and Supply Chain teams to resolve manufacturing issues.
• Evaluate engineering changes and ensure that affected drawings, BOMs, machine programs, tooling, procedures, and work instructions are updated before implementation.
• Support ECN/ECO implementation and maintain proper revision control.
• Monitor manufacturing performance through FPY, yield, defect rate, cycle time, downtime, OEE, UPH, scrap, rework, and cost data.
• Ensure manufacturing processes comply with customer, quality, safety, and regulatory requirements.

Qualifications

Qualifications

• Bachelor’s degree in Mechatronics, Electronics, Electrical, Industrial, Mechanical, Manufacturing Engineering, or a related discipline.
• At least three to five years of Process Engineering experience in a power-supply or electronics-manufacturing environment.
• Experience supporting NPI, process development, pilot builds, production transfer, and mass-production ramp-up.
• Experience in power-supply PCBA, SMT, final assembly, testing, and process improvement is preferred.

Required Knowledge and Skills

• Knowledge of New Product Introduction and production-ramp processes.
• Strong PCBA manufacturing knowledge, including SMT, soldering, inspection, testing, assembly, and box-build processes.
• Ability to perform DFM and DFA reviews for PCBAs and mechanical assemblies.
• Ability to prepare clear, accurate, and operator-friendly work instructions and visual aids.
• Experience using SAP for BOM, routing, material, production, or engineering-change activities.
• Ability to read and understand engineering drawings, schematics, BOMs, specifications, and technical documents.
• Knowledge of PFMEA, Control Plans, SPC, MSA, process capability, and root-cause analysis.
• Familiarity with IPC-A-610, J-STD-001, and relevant electronics-manufacturing standards is preferred.
• Proficiency in AutoCAD 2D and Microsoft Office, particularly Excel and PowerPoint.
• Good training, communication, analytical, and problem-solving skills.
• Ability to work independently and cooperate effectively with cross-functional teams.