Production Operator

Position: Operator - Mechanical Assembly

Work Location: Shamshabad, Hyderabad

Role & responsibilities :

Box Build & Mechanical Assembly

• Plan, implement, and support complete box build assemblies including:

• PCB integration into enclosures

• Cable harness routing and termination

• Mechanical fitting, fastening, and torque control

• Interpret mechanical drawings, BOMs, and assembly instructions

• Ensure proper alignment, sealing, gasket fitting, and EMI shielding

• Drive improvements in assembly methods, ergonomics, and cycle time

2. Bonding, Potting & Conformal Coating

• Define and control processes for:

• Bonding (adhesives, sealants, RTV, epoxy)

• Potting & encapsulation (thermal, electrical insulation, vibration protection)

• Conformal coating (acrylic, silicone, urethane, parylene)

• Select materials based on thermal, environmental, and electrical requirements

• Establish process parameters, curing cycles, masking techniques

• Ensure compliance with IPC standards (IPC-A-610, IPC-CC-830, J-STD-001)

• Troubleshoot defects such as:

• Voids, bubbles, delamination

• Coating thickness variation

• Incomplete curing

3. NPI (New Product Introduction) Engineering

• Lead end-to-end NPI activities from proto to mass production:

• Feasibility analysis

• Process design and validation

• Line setup and pilot builds

• Coordinate with design, quality, supply chain, and customers

• Prepare:

• Work Instructions (WI), SOPs

• PFMEA, Control Plans

• Process flow diagrams

• Conduct trial builds, design validation, and yield improvement

4. Engineering Modifications / Change Management

• Implement and validate Engineering Change Orders (ECO/ECN)

• Evaluate impact of changes on:

• Process capability

• Production efficiency

• Product reliability

• Update documentation, tooling, and fixtures accordingly

• Support root cause analysis (RCA) and corrective actions (CAPA)

5. Process Improvement & Quality

• Drive continuous improvement (Kaizen, Lean, Six Sigma principles)

• Improve FPY (First Pass Yield), reduce rework and scrap

• Monitor process KPIs:

• Cycle time

• Yield

• Defect rates

• Work closely with QA for:

• Failure analysis

• Reliability testing

• Audit compliance

6. Tooling & Equipment Management

• Define and validate fixtures, jigs, and assembly tools
• Support automation opportunities in coating/dispensing processes
• Maintain equipment calibration & preventive maintenance plans

7. Documentation & Compliance

• Ensure adherence to:

• IPC / ISO standards

• Customer requirements

• ESD and safety guidelines

• Maintain accurate:

• Process documentation

• Build records

• Traceability logs

Preferred candidate profile

• Strong knowledge of:

• Box build assembly processes

• Mechanical design integration

• Adhesives, potting compounds, conformal coatings

• Familiarity with:

• IPC standards (A-610, J-STD-001, CC-830)

• CAD drawings interpretation

• Understanding of:

• Thermal management

• EMI/EMC considerations

• Environmental protection methods

Education & Experience

• Diploma in Mechanical / Electronics
• 5 to 12 years in EMS / electronics manufacturing environment
• Experience in box build and NPI engineering preferred

Preferred Qualifications

• IPC certification (CIT/CIS)
• Six Sigma Green Belt / Lean certification
• Experience with automation in coating/potting dispensing systems
• Exposure to aerospace, automotive, or high-reliability electronics