Senior Process Engineer
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Key details
Job Description
- Develop cable and harness manufacturing processes for prototype and early production: wire prep, crimp, termination, shield and braid termination, backshell and strain relief, overmold and potting, breakout and routing
- Author manufacturing planning and documentation — work instructions, formboard layouts, wire lists, MBOMs, routings, and travelers — and keep them current as the configuration moves
- Establish and hold process controls: crimp height and pull-test sampling plans, tool verification and calibration intervals, cure and cycle parameters, and ESD controls
- Design, source, build, and prove out tooling and fixtures: formboards, crimp tooling and positioners, hold-downs, pull-test setups, and overmold tooling
- Own non-RF harness electrical test, including test programs, adapter cables, fixtures, and failure disposition with engineering
- Review RF cable assembly test criteria with engineering, flow them to suppliers, and assess incoming test data and CoCs against what was specified
- Build the manufacturing data package for source transfer and own the transition plan: timeline, tooling duplication or shipment, operator training, dual-source strategy, and the criteria that close out in-house build
- Lead supplier process qualification, first article, on-site audits, and build readiness reviews, and serve as the technical point of contact for supplier escapes, deviations, and changes. Hold suppliers to the documented process, not to a phone call
- Provide specific, actionable DFM and DFT feedback to electrical design: connector selection, wire and jacket callouts, service loops, breakout geometry, labeling, and harness segmentation for build and field repair
- Perform capacity analysis, takt and line balance, and floor layout for in-house prototype and pilot cells, and validate supplier capacity against rate demand
- Lead RCCA on process escapes and field returns, with effectiveness verified, whether the escape is ours or a supplier's. Drive improvement in yield, cycle time, scrap, and rework, and support MRB disposition
- Train technicians to the documented method and confirm they can execute it. Where the method is wrong, fix the method
- Uphold 5S, FOD and ESD control, and shop safety daily, and hold others to the same standard
- Perform other duties as directed
- Bachelors degree in Mechanical, Industrial or Electrical Engineering or equivalent degree. In lieu of a degree 10+ years of progressive relevant experience
- 'U.S. Person' as defined by 22 CFR § 120.62 required due to ITAR regulations, which includes U.S. citizens, lawful permanent residents (Green Card holders), or protected individuals under asylee or refugee status
- 5+ years of manufacturing or process engineering, with hands-on depth in cable, harness, or electromechanical assembly
- Experience in crimp and termination processes and rugged connector families — circular MIL-spec, micro-D, D-sub, RF/coax — including shield and braid termination
- Working knowledge of IPC/WHMA-A-620 and J-STD-001, and the ability to apply and defend acceptance criteria on the floor
- Experience taking a product from prototype into production
- Harness test development for non-RF assemblies: continuity and hipot systems, fixture and adapter design, and test program creation
- Proven RCCA capability using structured problem solving, with evidence of preventive action rather than containment only
- Fluent with schematics, wire lists, interconnect diagrams, and mechanical drawings including GD&T
- Practical command of lean principles: standard work, line balancing, and cell layout
- Familiarity with PLM, ERP, and MES systems and the handoff between them
- Comfortable working in the gap between engineering and production, able to hold a technical position with engineers while staying credible with technicians
- Demonstrated experience transferring a process to an external supplier: data package development, process qualification, and first article at source
- Ownership of a product through a full production ramp, including a capacity model, line layout, or rate readiness plan you personally built
- Active Secret clearance
- Hands-on RF cable assembly or RF test experience, or working knowledge of RF test methods sufficient to evaluate supplier data
- Mixed-commodity background: cable plus mechanical or electronics assembly
- UAV, experimental aircraft, or low-volume/high-mix aerospace experience, ideally at a company moving from prototype to rate
- Experience with automated wire process
- ing equipment and harness design tools with 3D-to-formboard flattening
- Overmolding, potting, and environmental sealing process development
- A continuous improvement project with quantified results, or formal Lean or Six Sigma training
- AS9100 environment, FAI/AS9102, and supplier quality experience
- IPC/WHMA-A-620 CIS or CIT certification
- CAD proficiency sufficient to model and detail tooling
- Position is working onsite at our headquarters in San Diego, CA.
- We welcome candidates who are local or open to relocating; relocation assistance is available and may be included in the offer package where appropriate.
- Requires sitting and standing for extended periods throughout the workday on the production floor
- Capable of lifting up to 50 lbs.
- Exposure to moderate noise, temperature variation, and typical shop-floor conditions
- Personal protective equipment (PPE) is provided and must be worn as required
- Base salary: $ base, commensurate with experience
- Equity: Meaningful equity grant in a growth-stage defense technology company
- We offer comprehensive medical, dental, and visions plans
- 401(k) Retirement Savings Plan to invest in your long-term retirement goals
- Equity grants for new hires
- Unlimited PTO
- Extremely generous company holiday calendar, including holiday hiatuses in July & December.
- Generous Parental Leave
- Lifestyle Spending Account
- FSA
- DCFSA
- HSA
- Hospital Indemnity insurance
- Critical Illness insurance
- Accident insurance
- Basic Life/AD&D, short-term and long-term disability insurance, 100% covered by Firestorm. Plus, the option to purchase additional life insurance for you and your family.
- Mental Health Resources: We provide free mental health resources 24/7 including therapy and more. Additional work-life services, such as free legal and financial support, are available to you as well.
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