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

1. 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

Operator - NPI & Engineering

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