Process Engineer Sr - New Product Introduction

Because of the need for consistent, in-person collaboration and/or the requirement to perform all work onsite due to the nature of this particular role, it will be performed fulltime on site. This means work will be conducted on location at a BAE Systems facility 100% of the time.
This position is on first shift working a 4/10 schedule Monday through Thursday. 

BAE Systems is looking for a Process Engineer Sr supporting Module & Box Build assemblies for the New Product Introduction Pilot Line. Our employees work on the world’s most advanced electronics – from detecting threats for F-35 pilots to illuminating the night for soldiers. Spanning air, land, sea, and space, we are developing the technology of tomorrow, delivered today. Drawing strength from our differences, we are innovating for the future, and you can, too! Our flexible work environment provides you a chance to change the world without giving up your personal life. We put our customers first – exemplified by our mission: “We Protect Those Who Protect Us®.”

The Electronic Warfare Integrated Manufacturing Center (EW-IMC) New Product Introduction (NPI) Pilot Line located in Nashua, NH is responsible for the early builds of new electronic and mechanical hardware designs. This includes the development and maturation of the associated build processes, programming, and tooling in preparation for rate production. This requires close collaboration with the design community, the receiving production teams, and requires being able to adapt to a rapidly changing environment. The NPI Pilot Line plays a critical, exciting, and unique role that helps ensure that future production runs are successful. This role is primarily focused on the Module/Box Build side of the NPI Line.

Process Engineering is a fast-paced, versatile, diverse, and critical role. Process Engineers are an essential catalyst in facilitating and executing to meet customer needs and providing crucial feedback to the production floor. Collaborative and dynamic in nature, this role must be adaptive, agile, and display ownership over responsibilities. Approaching tasks with a sense of urgency, being open to change, maintaining a positive attitude, and being a self-starter are all important attributes to being successful within the NPI team.

In this role, you will:

• Utilize Rapid Process Manufacturing (RPM) process for work plan creation
• Manage Process Change Requests (PCRs)
  • Submit Process Change Requests in the Paperless system
  • Perform Process Engineering reviews of work instructions in the Paperless system for clarity and content
  • Verify incorporation(s) to the process plan
• Provide timely floor support
  • Troubleshooting of product in the assembly process
  • Real-time clarification of work instruction to staff
  • Process updates in accordance with feedback and best practice
  • Support and ownership of factory equipment
• Responsibility over the build process
  • Maintain order of operations, build process efficiency
  • Ensure content clarity and conformance to industry and BAE standards
  • Verify and meet customer needs (Prototype vs Eng.-Use-Only vs Production)
• Ownership of product quality
  • Drive defects to root cause
  • Advocate for and implement preventative measures and solutions
  • Communicate feedback to feeder factories, next higher assembly build locations, supply chain, and QA stakeholders
  • Perform defect and HPU deep dive analysis
  • Communicate defects and corrective actions at periodic meetings to leadership and program stakeholders
• Disposition rework, facilitate and participate in the PMRB process
• Coordinate, populate, and facilitate Transition to production (TTP) process in a timely manner
  • Own the TTP process for assigned assemblies
• Participate in PFMEA, DFMEA, MFA (Manufacturing Feasibility Analysis), and CDR/PDR/IDR
• Demonstrate ownership of programs
  • Function as the primary point of contact
  • Liaison to Program, P2L, etc.
  • Maintain process engineering program spreadsheet
• Design, fabricate, and validate process aides, fixtures, and tooling designs
• Propose, setup, and validate factory equipment
• Provide Estimated Time of Completions (ETCs) for Non-Recurring Engineering (NRE)
• Perform safety assessments
• Identify, propose, and execute Continuous Improvement (CI) initiatives