Process Engineer 3

Process Engineer 3

Full Time + Benefits (Medical, Dental, Vision, 401k with Company Match, PTO)

Job Type: Onsite

Salary Range: $127,800 - $147,000, DOE

Location: Milpitas, CA

Fralock is an engineered solutions provider of specialty components and subassemblies using advanced materials for high reliability, severe environment, and technically challenging applications. We develop and manufacture custom integrated solutions. Established in 1967, we are a critical solutions provider to Fortune 500 corporations, government, and targeted OEMs in a variety of industries including Semiconductor Equipment Manufacturing, Medical and Life Science, Aerospace and Defense, Industrial, Electronics, and Energy. Fralock is headquartered in Valencia, CA with manufacturing locations located throughout Northern and Southern California.

VISION

To be recognized by our customers as a leading solutions provider of proprietary engineered advanced materials for high reliability, severe environment, and technically challenging applications.

MISSION

To create value, profitably grow, and share our success with all stakeholders.

CULTURE

• Respect – We treat others the way they want to be treated.
• Integrity – We practice a high standard of ethics in our business dealings with customers, employees, and suppliers.
• Responsiveness – We have a sense of urgency in responding to internal and external requests, and work proactively to solve problems.
• Excellence/Competence – We empower our people to continuously improve and execute high quality work.
• Teamwork – We work together to achieve Fralock business objectives by communicating at a high level, by listening and having clarity in our expectations of one another.
• Individual Accountability and Personal Responsibility – We do what we have committed to do when we committed to doing it.
• Continuous Improvement across all segments of the company

Job Summary

The Process Engineer is responsible for developing, implementing, optimizing, and sustaining manufacturing processes used in the production of printed circuit boards (PCBs). This role predominantly provides technical leadership for lithography process operations, including substrate preparation, photoresist coating and lamination, UV exposure and imaging, photoresist development, and photoresist removal. The Process Engineer works closely with Manufacturing, Maintenance, Quality, and Product Engineering teams to improve yield, reliability, throughput, and cost while ensuring compliance with safety, environmental, customer, and regulatory requirements.

Essential Duties and Responsibilities

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. Reasonable accommodation may be made to enable qualified individuals with disabilities to perform essential job duties.

Essential duties include, but are not limited to:

• Serve as the technical subject matter expert (SME) in a multilayer rigid/flex PCB fabrication facility for lithography process operations, which includes processes such as substrate preparation, photoresist coating and lamination, UV exposure and imaging, photoresist development, and photoresist removal.

• Drive development and new product introduction (NPI) by performing activities such as:

  • Researching and evaluating capital equipment, tooling, automation, and process improvements to improve or expand the capability of the manufacturing line.
  • Evaluating proposed new equipment and tooling for necessary and desired functionality.
  • Identifying the best equipment, setup, tooling, and process sequences for new products.
  • Developing and communicating ROI analyses for proposed new methods, processes, or equipment for different target audiences.
  • Developing and qualifying new processes and equipment using standard methodologies such as Design of Experiments (DOE), process capability analyses, and Gage R&R.
  • Developing and revising process-related parameters and documentation such as process failure mode and effects analyses (PFMEAs), key process indicators (KPIs), statistical process controls (SPCs), standard operating procedures (SOPs), and work instructions.

• Improve current production methodology by performing activities such as:

  • Leading and supporting continuous improvement processes focused on goals such as safety, quality, efficiency, cycle time reduction, and cost savings.
  • Analyzing engineering drawings, ERP data, and other relevant information to evaluate time, cost, materials, and labor estimates.
  • Evaluating risks and benefits of proposed manufacturing process improvements.
  • Validating the implementation and impact of accepted manufacturing process changes.
  • Revising process-related documentation as necessary.

• Sustain current production output by partnering with the Manufacturing, Maintenance, and Quality groups to perform activities such as:

  • Analyzing yield losses, nonconformances, and customer returns to identify root causes and implement corrective and preventive actions (CAPA).
  • Troubleshooting equipment issues and improving equipment reliability and uptime.
  • Promoting best known practices to ensure product quality, consistency, cycle time, and throughput.
  • Monitoring chemical processes, bath chemistry, equipment performance, and environmental compliance requirements.

• Support internal, customer, and regulatory audits as required.

Required Skills

• Must have excellent written and verbal communication skills.
• Ability to understand and create documentation required for key responsibilities and communication of information.
• Experience creating and presenting technical and project information to different types of audiences.
• Experience reading and interpreting engineering drawings, specifications, and manufacturing documents.
• Experience working in photolithography operations.
• Experience working in wet-process manufacturing environments.
• Experience with Design of Experiments (DOE) and process validation activities.
• Experience with data analysis necessary to identify and evaluate operational improvements, such as tracking KPIs, process capability (CpK), and other performance metrics.
• Experience using standardized troubleshooting and issue-tracking tools and methodologies (e.g., 5-Whys, DACA, DMAIC, 8D, Fishbone Diagrams).
• Familiarity with relevant standards (e.g., ISO 9000, ISO 13485, AS9100, IPC-6012, and IPC-A-600).
• Familiarity with Manufacturing and Quality processes used in manufacturing environments (e.g., 6S, Lean, Six Sigma).
• Familiarity with common software packages used in manufacturing environments (e.g., ERP systems, SPC systems, Microsoft Office Suite).
• Familiarity with process sequencing and individual process operations in a PCB fabrication environment, such as photolithography, metal plating and finishing, cleaning and etching, and inspection.

Preferred Skills

• Six Sigma Green Belt or Black Belt Certification.

• Expertise working in photolithography operations.

• Expertise in process sequencing and individual process operations in a PCB fabrication environment, such as photolithography, metal plating and finishing, cleaning and etching, and inspection.

• Expertise in troubleshooting methodologies.

• Experience using inspection systems/methodologies for testing and root cause analysis.

• Experience with implementation of relevant standards (e.g., ISO 9000, ISO 13485, AS9100, IPC-6012, and IPC-A-600).

• Experience working with ERP systems (e.g., Made-2-Manage).

• Familiarity with basic project/program management principles.

• Familiarity with aerospace, semiconductor, medical, and automotive industries.

Education Requirements

• Bachelor’s degree in manufacturing engineering, chemical engineering, mechanical engineering, industrial engineering, or related field and a minimum of seven (7) years of related experience; or Master’s degree and five (5) years of related experience.
• Minimum of three (3) years of engineering experience in a manufacturing environment.

Physical Requirements

• Frequent use of hands for handling equipment and tools.
• Ability to perform similar operations and tasks for 6 to 8 hours.
• Ability to sit and stand for 6 to 8 hours.
• Ability to lift up to 25 lbs. frequently.
• Ability to lift, push, and pull up to 50 lbs. occasionally.
• Ability to bend and reach for 6 to 8 hours.

Working Conditions

• Work performed indoors in a temperature-controlled environment frequently.
• Required use of PPE including safety glasses, gloves, and safety-toed footwear.
• While performing the duties of this job, will regularly be exposed to moving high-speed machinery and mechanical parts. Will occasionally be exposed to machine oils and hazardous materials.
• Travel up to 10% as required.

This position requires access to information controlled under the International Traffic in Arms Regulations (ITAR) or the Export Administration Regulations (EAR), the successful candidate must be a "U.S. person" as defined in the ITAR and EAR (which generally means (i) be a citizen or national of the United States; or (ii) be a lawful permanent resident of the United States; or (iii) have been admitted to the United States as a refugee, or have been granted asylum, as specified under applicable law.

All offers of employment at Fralock are contingent upon clear results of a background check. Background checks may include some or all the following depending on job title and responsibilities:

• Social Security Verification
• Prior Employment Verification
• Criminal History
• Personal and Professional References
• Motor Vehicle Records
• Credit History

Fralock provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. #ZR