Process Development Engineer

Role Purpose

The Process development lead for Fiber Array Units (FAUs) will oversee the design, optimization, and implementation of manufacturing processes for fiber array products. This role involves working at the intersection of technology, engineering, manufacturing, and quality assurance to ensure the highest levels of efficiency, reliability, and product performance. The ideal candidate will have a strong technical background in fiber optics, micro-assembly processes, and materials science, as well as experience leading process development in high-tech or optical manufacturing environments.

Key Responsibilities

• Process Design and Optimization: Develop, validate, and implement scalable manufacturing processes for fiber array units; Optimize processes to improve yield, cycle time, and cost-effectiveness; Design and conduct experiments to evaluate process reliability and performance.
• Cross-Functional Collaboration: Collaborate with R&D, engineering, and production teams to transition new product designs into full-scale production; Partner with supply chain and procurement teams to select materials, components, and equipment; Work closely with quality assurance to meet product specifications and compliance standards.
• Technology and Equipment Development: Identify and integrate new technologies and equipment to enhance manufacturing capabilities; Work with suppliers and vendors on the development and customization of specialized tools and fixtures.
• Process Documentation and Training: Create and maintain detailed process documentation, including work instructions, standard operating procedures (SOPs), and failure mode effect analysis (FMEA); Train production teams to ensure consistent adherence to manufacturing protocols. 
• Continuous Improvement: Lead efforts in lean manufacturing, Six Sigma, or other methodologies to drive continuous improvement. Monitor key performance indicators (KPIs) to identify areas for process enhancement.
• Problem-Solving and Troubleshooting: Address and resolve process-related issues in production, working proactively to prevent recurring problems; Analyze root causes of process failures and implement corrective actions.
• Compliance and Safety: Ensure compliance with industry standards, such as Telcordia GR-1209/1221 and other relevant optical and fiber-optic standards; Promote workplace safety and enforce safe handling of optical fibers and chemicals. 

Experiences/Education - Required

• Proven track record of successfully scaling processes from prototype to production.
• Strong knowledge of fiber optic components, including arrays, connectors, and splicing.
• Proficiency in process control techniques, statistical analysis, and software tools (e.g., Minitab, JMP).
• Familiarity with CAD software for fixture design and automation tools for process development.
• Understanding of cleanroom practices and handling of precision optical components.
• Fluent in English for communication, presentation, and documentation 
• Hands-on experience with fiber array units, fiber alignment, or micro-assembly processes is highly desirable.
• Skilled in statistical data analysis and Design of Experiments for process problem-solving
• Established laboratory operations and protocols