Process Engineer - Circuit Card

Job Description
BAE Systems is seeking a Process Engineer to support Circuit Card Assembly (CCA) manufacturing operations for high-reliability aerospace and defense electronics.
This role is responsible for developing, optimizing, and sustaining manufacturing processes across CCA process and conformal coating operations. The Process Engineer will support process improvements, yield enhancement, defect reduction, and equipment performance, while contributing to New Product Introduction (NPI) and Non-Recurring Engineering (NRE) builds. This position requires strong collaboration with Operations, Quality, Maintenance, and Program teams to ensure compliance with AS9100 and IPC standards.
Job Duties

• Support daily manufacturing operations for CCA assembly and conformal coating
• processes.
• Monitor and maintain process performance for: conformal coating systems (manual, automated and selective, masking, curing, and inspection)
• Troubleshoot process and equipment issues using root cause analysis and corrective actions.
• Assist in developing and optimizing process parameters, recipes, and work instructions for coating and underfill processes.
• Support Statistical Process Control (SPC) initiatives by collecting and analyzing process data.
• Participate in yield improvement and defect reduction efforts.
• Support NPI activities, including prototype builds, process setup, coating trials, and DFM reviews.
• Assist with NRE builds, including new process introduction, and early production support.
• Support equipment qualification and validation activities (IQ/OQ/PQ) for conformal coating systems.
• Work with Quality Engineering to ensure compliance with AS9100, IPC-A-610, J-STD-001, and coating standards (e.g., IPC-CC-830 where applicable).
• Collaborate with Maintenance teams to improve equipment uptime.
• Maintain and update process documentation, including method sheets, PQP's, PFMEA's, control plans, and process flows.
• Participate in continuous improvement initiatives to improve efficiency, reduce waste, and lower manufacturing costs.
• Follow and support safety requirements, including LOTO procedures, chemical handling, and Job Safety Analysis (JSA)

Key Responsibilities

• Process Support & Optimization
• Support process development and optimization for SMT, SPI, AOI, reflow, and Wash operations
• Assist in improving process capability (Cp/Cpk) and yield performance
• Monitor process trends and support corrective actions
• Equipment & Process Control
• Support operation and optimization of: Conformal Coating processes
• Assist with process validation and equipment qualification activities
• Ensure process controls are maintained and followed
• NPI & NRE Support
• Assist in developing manufacturing processes for new products and coating requirements
• Help transition products from development to production
• Cross-Functional Collaboration
• Work with Operations, Quality, Maintenance, Engineering, and SHE teams
• Support production readiness and issue resolution
• Communication of process issues and improvement opportunities.

Required Education, Experience, & Skills

• Bachelor's degree in engineering (Manufacturing, Mechanical, Electrical, or related field)
• 2-5 years of experience in electronics manufacturing.
• Basic understanding of CCA assembly processes
• Knowledge of IPC-A-610 and J-STD-001 standards
• Familiarity with AS9100 quality systems
• Experience supporting NPI or development builds
• Strong problem-solving and analytical skills
• Ability to work in a fast-paced manufacturing environment

Preferred Education, Experience, & Skills

• Experience with SMT, SPI, AOI, reflow ovens, inline wash
• Familiarity with SPC (Statistical Process Control)
• Knowledge of IPC-CC-830 coating standards
• Experience in aerospace or defense manufacturing
• Lean Manufacturing or Six Sigma training (Green Belt preferred)

Pay Information
Full-Time Salary Range: $79365 - $134921
Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.
Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.
About BAE Systems Electronic Systems
BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace and security company which delivers a full range of products and services for air, land and naval forces, as well as advanced electronics, security, information technology solutions and customer support services. Improving the future and protecting lives is an ambitious mission, but it's what we do at BAE Systems. Working here means using your passion and ingenuity where it counts - defending national security with breakthrough technology, superior products, and intelligence solutions. As you develop the latest technology and defend national security, you will continually hone your skills on a team-making a big impact on a global scale. At BAE Systems, you'll find a rewarding career that truly makes a difference. Electronic Systems (ES) is the global innovator behind BAE Systems' game-changing defense and commercial electronics. Exploiting every electron, we push the limits of what is possible, giving our customers the edge and our employees opportunities to change the world. Our products and capabilities can be found everywhere - from the depths of the ocean to the far reaches of space. At our core are more than 14,000 highly talented Electronic Systems employees with the brightest minds in the industry, we make an impact - for our customers and the communities we serve.
This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.