Senior Process Engineer - Magnetics

1 day ago Be among the first 25 applicants Get AI-powered advice on this job and more exclusive features. Exxelia is a global leader in the design and manufacture of high-reliability passive electronic components and subsystems. We specialize in serving the world's most demanding markets, including aviation, defense, space, and medical industries. We are seeking an experienced and highly skilled Senior Process Engineer to join our dynamic Magnetics team. The successful candidate will be a subject matter expert responsible for developing, implementing, and optimizing manufacturing processes for our custom magnetic components, such as transformers and inductors. This role is critical for ensuring our products meet stringent quality standards, improving manufacturing efficiency, and driving continuous improvement initiatives in a high-mix production environment. Key Responsibilities Process Development & Optimization: Design, develop, and qualify robust manufacturing processes for new and existing magnetic products. This includes winding, core stacking, soldering, potting/encapsulation, and final assembly. Continuous Improvement: Lead continuous improvement projects using Lean Manufacturing, Six Sigma, and SPC (Statistical Process Control) methodologies to enhance yield, reduce scrap, improve cycle times, and lower manufacturing costs. Root Cause Analysis: Investigate and resolve complex manufacturing issues and product failures. Implement effective corrective and preventive actions (CAPA) to address root causes. New Product Introduction (NPI): Collaborate closely with the Design Engineering team to ensure Design for Manufacturability (DFM). Develop process flows, work instructions, and tooling for new products transitioning from design to full-scale production. Equipment & Tooling: Specify, justify, and commission new manufacturing equipment and tooling. Develop and manage equipment qualification protocols. Documentation & Training: Create and maintain comprehensive process documentation, including work instructions, process specifications, and standard operating procedures (SOPs). Train and certify production operators on new processes and equipment. Technical Support: Serve as the primary technical resource for the magnetics production floor, providing hands-on support to troubleshoot process and equipment issues. Compliance & Quality: Ensure all processes comply with internal quality management systems (AS9100) and relevant industry standards. Support quality audits and customer inquiries. Required Qualifications: Bachelor of Science in Engineering (Mechanical, Electrical, Industrial, or Materials Science preferred). Minimum of 5-7 years of process engineering experience in a manufacturing environment. Demonstrated experience with the manufacturing of electromagnetic components. Proven experience in leading continuous improvement initiatives (Lean, Six Sigma Green Belt, or equivalent). Excellent problem-solving skills with experience in structured methodologies like 8D, FMEA, and DMAIC. Preferred Qualifications: Experience in the aerospace, defense, or high-reliability electronics industry. In-depth knowledge of AS9100 and MIL-STD quality standards. Proficiency with CAD software (e.g., SolidWorks, AutoCAD) for fixture and tool design. Strong understanding of core manufacturing principles such as winding techniques, soldering (J-STD-001 is a plus), potting/encapsulation, and electrical testing of magnetic components. Experience with vacuum pressure impregnation (VPI) and encapsulation processes. Familiarity with ERP systems and statistical analysis software (e.g., Sage). Exxelia is committed to equal opportunity for all, without regard to race, religion, color, national origin, citizenship, sex, sexual orientation, gender identity, age, veteran status, disability, genetic information, or any other protected characteristic. Seniority level

Seniority level Mid-Senior level Employment type

Employment type Full-time Job function

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