Process Engineering Manager – DF

Roles & Responsibilities:

The Process Engineering Manager is responsible for establishing, maintaining, and continuously improving the manufacturing processes required to achieve safe, stable, scalable, high-quality, and cost-effective DF operations for CISCO. The role provides end-to-end process ownership from NPI / transfer through mass production, ensuring that manufacturing processes meet CISCO requirements, FOXCONN standards, quality expectations, and operational targets.

Core Responsibilities:

Process Ownership: Own the end-to-end manufacturing process for PCBA, SMT, Final Assembly and DF Integration. Define standardized processes, work instructions, process controls and process parameters.

NPI / Product Transfer: Lead process readiness for new products, BU transfers and production ramp-ups. Ensure DFM/DFA, PFMEA, Control Plan, process flow and tooling readiness before mass production.

Process Optimization: Identify and eliminate process losses through Lean Manufacturing, Six Sigma, Kaizen, DOE, SPC and structured problem-solving methodologies.

Production Stability: Ensure processes are capable, repeatable and stable during ramp and mass production. Establish reaction plans and escalation mechanisms for process abnormalities.

Yield & Quality Improvement: Drive FPY, yield, defect reduction, rework reduction and process capability improvement. Lead root-cause analysis for recurring process-related defects.

Capacity & Scalability: Validate process capacity for current and future DF volumes. Analyze equipment, labor, cycle time, line balance, test capacity and bottlenecks to support incremental BU and volume growth.

Automation: Identify and implement automation opportunities in partnership with Manufacturing Engineering, IT and automation teams. Evaluate and adopt proven automation from other FOXCONN DF sites.

Standardization: Establish common process standards across DF BUs and manufacturing lines. Promote replication of proven best practices between FGD, FGP, FTX, FJZ and other DF sites.

Customer Interface: Act as the primary Process Engineering representative during CISCO technical reviews, escalations, audits, NPI and process-improvement discussions.

Problem Solving: Lead structured technical problem solving using 8D, 5 Why, Fishbone, DOE and other appropriate methodologies. Ensure permanent corrective actions are implemented and verified.

Process Documentation: Ensure PFMEA, Control Plan, SOP/WI, process flow, tooling specifications, process parameters and change-control documentation are current and controlled.

Change Management: Lead engineering change implementation, including ECO/ECR assessment, risk analysis, validation, qualification and production implementation.

***Equipment & Tooling:***Define process equipment, tooling, fixtures and automation requirements. Ensure equipment readiness, qualification, preventive maintenance and process capability.

Training & Certification: Establish technical training and certification requirements for Process Engineers, supervisors and production personnel. Maintain competency matrices and periodic re-certification.

Performance Management: Establish and monitor process KPIs including FPY, yield, DPPM, downtime, cycle time, OEE, scrap, rework and process capability.

Cross-Functional Leadership: Lead collaboration between PE, Product Engineering, Test Engineering, Quality, Manufacturing, Planning, Materials, IT and Operations.

Continuous Improvement: Establish a structured CI roadmap focused on productivity, quality, automation, digitalization and cost reduction.

DF Process Manager for CISCO as customer-Specific Responsibilities:

The Process Engineering Manager should specifically ensure:

DF Operational Readiness:

Process readiness for every BU transfer and production ramp.

Standardized manufacturing processes across DF BUs.

Readiness of PCBA Integration Test Pack/Ship processes.

Clear ownership of process KPIs and escalation points.

Risk assessment before volume increases or BU transfers.

Scalability:

Validate line capacity, labor, equipment, test capacity and cycle time.

Identify bottlenecks before they impact CISCO commitments.

Develop capacity scenarios for normal, peak and incremental volume.

Maintain a capacity and process-risk dashboard.

Customer Excellence:

Provide technical leadership during CISCO reviews.

Present process performance, risks, corrective actions and improvement plans.

Respond rapidly to CISCO process-related escalations.

Ensure customer commitments are translated into measurable internal actions.

Key Deliverables: Process Flow / Process Architecture, PFMEA, Control Plan, Standard Work / Work Instructions, Process Capability Studies, Line Balancing & Cycle-Time Analysis, Capacity Validation, Process Readiness Checklist, NPI / Transfer Readiness, Engineering Change Management, Process KPI Dashboard, Yield / FPY Improvement Roadmap, Automation Roadmap, Process Risk Register, Training & Certification Matrix

Recommended KPIs: Quality: FPY, RTY, DPPM, MRB, RMA, defect rate, rework, scrap, Process

Capability: Cp, Cpk, process stability, SPC compliance

Productivity: UPH, cycle time, OEE, labor efficiency

Capacity: Capacity utilization, bottleneck rate, capacity gap

NPI / Transfer: Readiness %, milestone adherence, issues closed

Problem Solving: 8D closure, recurrence rate, corrective-action effectiveness

Automation: Automation utilization, labor savings, ROI, defect reduction

Standardization: Process compliance, audit findings, replication rate

Training: Certification %, competency coverage, re-certification compliance

Customer: CISCO escalations, response time, action closure, audit performance

Leadership Expectations:

The Process Engineering Manager is expected to operate as a business and technical leader, not only as a functional engineering manager.