Operator - NPI & Engineering

Position: Operator - NPI & Engineering Organization: Cyient DLM Limited Location: Shamshabad, Hyderabad Job Summary Responsible for leading and supporting box build assembly processes including mechanical assembly, bonding, potting, and conformal coating operations in an EMS environment. The role also involves NPI (New Product Introduction) execution, engineering changes, process optimization, and production readiness for new and existing products.

Key Responsibilities

• Box Build & Mechanical Assembly Plan, implement, and support complete box build assemblies including: PCB integration into enclosures Cable harness routing and termination Mechanical fitting, fastening, and torque control Interpret mechanical drawings, BOMs, and assembly instructions Ensure proper alignment, sealing, gasket fitting, and EMI shielding Drive improvements in assembly methods, ergonomics, and cycle time 2. Bonding, Potting & Conformal Coating Define and control processes for: Bonding (adhesives, sealants, RTV, epoxy) Potting & encapsulation (thermal, electrical insulation, vibration protection) Conformal coating (acrylic, silicone, urethane, parylene) Select materials based on thermal, environmental, and electrical

requirements

Establish process parameters, curing cycles, masking techniques Ensure compliance with IPC standards (IPC-A-610, IPC-CC-830, J-STD-001) Troubleshoot defects such as: Voids, bubbles, delamination Coating thickness variation Incomplete curing 3. NPI (New Product Introduction) Engineering Lead end-to-end NPI activities from proto to mass production: Feasibility analysis Process design and validation Line setup and pilot builds Coordinate with design, quality, supply chain, and customers Prepare: Work Instructions (WI), SOPs PFMEA, Control Plans Process flow diagrams Conduct trial builds, design validation, and yield improvement 4. Engineering Modifications / Change Management Implement and validate Engineering Change Orders (ECO/ECN) Evaluate impact of changes on: Process capability Production efficiency Product reliability Update documentation, tooling, and fixtures accordingly Support root cause analysis (RCA) and corrective actions (CAPA) 5. Process Improvement & Quality Drive continuous improvement (Kaizen, Lean, Six Sigma principles) Improve FPY (First Pass Yield), reduce rework and scrap Monitor process KPIs: Cycle time Yield Defect rates Work closely with QA for: Failure analysis Reliability testing Audit compliance 6. Tooling & Equipment Management Define and validate fixtures, jigs, and assembly tools Support automation opportunities in coating/dispensing processes Maintain equipment calibration & preventive maintenance plans 7. Documentation & Compliance Ensure adherence to: IPC / ISO standards Customer

requirements

ESD and safety guidelines Maintain accurate: Process documentation Build records Traceability logs

Requirements

Technical

Skills

Strong knowledge of: Box build assembly processes Mechanical design integration Adhesives, potting compounds, conformal coatings Familiarity with: IPC standards (A-610, J-STD-001, CC-830) CAD drawings interpretation Understanding of: Thermal management EMI/EMC considerations Environmental protection methods Soft

Skills

Problem-solving and analytical thinking Cross-functional collaboration Strong communication and documentation

skills

Ability to manage multiple NPI projects

Education

&

Experience

Diploma in Mechanical / Electronics 5–12 years in EMS / electronics manufacturing environment

Experience

in box build and NPI engineering preferred Preferred

Qualifications

IPC certification (CIT/CIS) Six Sigma Green Belt / Lean certification

Experience

with automation in coating/potting dispensing systems Exposure to aerospace, automotive, or high-reliability electronics Key Performance Indicators (KPIs) NPI on-time launch success First Pass Yield (FPY) Reduction in defects (coating/potting failures) Engineering change implementation cycle time Productivity improvement

Establish process parameters, curing cycles, masking techniques Ensure compliance with IPC standards (IPC-A-610, IPC-CC-830, J-STD-001) Troubleshoot defects such as: Voids, bubbles, delamination Coating thickness variation Incomplete curing 3. NPI (New Product Introduction) Engineering Lead end-to-end NPI activities from proto to mass production: Feasibility analysis Process design and validation Line setup and pilot builds Coordinate with design, quality, supply chain, and customers Prepare: Work Instructions (WI), SOPs PFMEA, Control Plans Process flow diagrams Conduct trial builds, design validation, and yield improvement 4. Engineering Modifications / Change Management Implement and validate Engineering Change Orders (ECO/ECN) Evaluate impact of changes on: Process capability Production efficiency Product reliability Update documentation, tooling, and fixtures accordingly Support root cause analysis (RCA) and corrective actions (CAPA) 5. Process Improvement & Quality Drive continuous improvement (Kaizen, Lean, Six Sigma principles) Improve FPY (First Pass Yield), reduce rework and scrap Monitor process KPIs: Cycle time Yield Defect rates Work closely with QA for: Failure analysis Reliability testing Audit compliance 6. Tooling & Equipment Management Define and validate fixtures, jigs, and assembly tools Support automation opportunities in coating/dispensing processes Maintain equipment calibration & preventive maintenance plans 7. Documentation & Compliance Ensure adherence to: IPC / ISO standards Customer

requirements

ESD and safety guidelines Maintain accurate: Process documentation Build records Traceability logs

Requirements

Technical

Skills

Strong knowledge of: Box build assembly processes Mechanical design integration Adhesives, potting compounds, conformal coatings Familiarity with: IPC standards (A-610, J-STD-001, CC-830) CAD drawings interpretation Understandi