Senior Process Development Engineer

Job Summary

The Process Development Engineer at Daylight will be responsible for supporting the development of laser modules from initial design through production.  Support includes manufacturing analysis, fixture development and integration of robotic tooling. They should have a strong understanding of equipment, documentation and testing of optical/laser products, systems, and subsystems. Working with a multi-disciplinary team, they will execute on prototyping, calculations, FMEA, builds, testing, capacity planning, and process development. The successful candidate would be able to compile/review data, perform both optical and mechanical analyses, build preventative and predictive maintenance requirements and plans for laser related equipment in manufacturing, and implement changes in the lab, and document those changes. They should additionally be an agile self-starter who is able to work independently and be receptive to ideas and feedback from the team.
 

Job Responsibilities

• Develop systematic processes for various laser packaging technologies (soldering, wire bonding, lid welding, adhesive bonding, hermeticity testing).
• Validate design intent and optimize manufacturability.
• Hands-on support of initial engineering prototype and production lasers builds. 
• Work with design engineers to ensure manufacturability of new products. 
• Troubleshoot engineering issues with root cause analysis. 
• Use SolidWorks and other design/analysis software.
• Perform statistical processing to establish control limits and monitor processes. 
• Document manufacturing processes to support new products and lifecycle changes (Work Instructions, ECO’s, and TDN’s). 
• Create and conduct validation test plans to qualify process changes. 
• Execute process improvements using lean manufacturing and six sigma methodologies. 
• Integrate information technologies with shop floor processes.  
• Support 5S, housekeeping and cleanliness standards throughout manufacturing.
• Set up data collection, analysis, and feedback to improve process performance.
• Design and implement process and production control methods, including identification, tracking and analysis (JMP, Minitab) of key process variables, KPP Capability Analysis, Cpk.
• Construct and execute controlled experiments (DOE and Gage R & R) to address yield, quality, and equipment issues.
• Purchase, fabricate, build, and test prototypes to retire key development risks.
• Interface with suppliers to evaluate new production equipment options and facilitate selection.  
• Assist MFG team on the design and implementation of production lines, work cells, fixtures, and other production equipment.

The ideal candidate will:

• Ability to work independently as well as with a team, providing regular reports on progress and status.
• Ability to work on projects in parallel.
• Good organization, able to balance lab work, meetings, and design work.
• Communicate clearly (written and oral) with other company personnel and customers as required, documenting analysis, test results, and design reviews.
• Support, communicate, reenforce and defend the mission, values, and culture of the organization.
   

Qualifications

• Bachelors Degree in an applicable engineering field with 5+ years applicable engineering experience (or equivalent combination of education/training and experience preferably in opto-mechanical, laser packaging, or manufacturing engineering.
• Competent technical expertise and application domain knowledge

The pay scale for this position is $101, 237/year - $157,169/year. The pay scale information is a general guideline only.  Several factors can influence the pay scale for a position including but not limited to, Federal Government contract labor categories and contract wage rates, collective bargaining agreements, geographic locations, business considerations, scope and responsibilities of the position, local or other applicable market conditions, and internal equity.  Other factors include the candidate's qualifications such as relevant prior work experience, specific skills and competencies, education/training, and certifications.