Highlights
The Process Engineer is responsible for performing assigned engineering duties involving manufacturing process control, troubleshooting, and research of manufacturing quality issues. USI/Asteelflash is actively looking for a highly organized and talented Process Engineer to help support the Engineering activities at our location in Milpitas, CA.
Numbers & Facts
| Location | Milpitas, California |
| Industry | Insurance |
| Company Size | 2,500 to 4,999 employees |
| Year Founded | 1994 |
| Website | http://ww2.usi.biz/Careers.aspx |
Description
USI/Asteelflash is actively looking for a highly organized and talented Process Engineer to help support the Engineering activities at our location in Milpitas, CA. The Process Engineer is responsible for performing assigned engineering duties involving manufacturing process control, troubleshooting, and research of manufacturing quality issues. Assists manufacturing engineering with process development. Interfaces with manufacturing and engineering during the development, installation, and maintenance of improved manufacturing methods and controls. This position is 100% onsite.
About The Job
Location: Milpitas, CA [Onsite]
Employment Type: Full-time, Exempt
Department: Engineering
Reports To: Engineering Manager
Location: Milpitas, CA [Onsite]
Employment Type: Full-time, Exempt
Department: Engineering
Reports To: Engineering Manager
Responsibilities:
Process Development & Optimization
- Develop, implement, and validate manufacturing processes for PCBA assembly (SMT, box build).
- Optimize production line layouts for efficiency and productivity.
- Define process parameters and control methods.
- Conduct time studies and capacity analysis.
New Product Introduction (NPI)
- Support product launch activities from prototype to mass production.
- Review Gerber files, BOMs, and assembly drawings for manufacturability (DFM/DFA).
- Create process flow charts, work instructions, and control plans.
- Coordinate pilot runs and process validation.
Equipment & Tooling Management
- Select and validate SMT equipment (printers, SPI, pick-and-place, reflow ovens, AOI).
- Support programming and optimization of equipment such as:
- SMT lines (e.g., equipment from companies like ASMPT, Panasonic, Fuji Corporation)
- Wave machines (e.g., Electrovert, SEHO, ERSA)
- Conformal coating systems (e.g., PVA, Nordson)
- Ensure preventive maintenance plans are in place.
- Troubleshoot process and equipment-related issues.
Quality & Continuous Improvement
- Analyze defects and implement corrective actions (8D, RCA, FMEA).
- Monitor KPIs such as FPY, OEE, yield, scrap, and cycle time.
- Implement poka-yoke and mistake-proofing solutions.
Documentation & Compliance
- Develop SOPs, process instructions, and engineering change documentation.
- Ensure compliance with IPC standards (e.g., IPC-A-610).
- Maintain process documentation in ERP/MES systems.
Cross-Functional Collaboration
- Work closely with production, quality, supply chain, and R&D teams.
- Interface with customers for technical discussions and audits.
- Provide technical training to operators and technicians.
Requirements:
Education/Qualification
- Bachelor’s degree in an engineering field or equivalent level of knowledge normally obtained through completion of a BS degree.
Experience (Years & Fields)
- Requires 4+ years of related experience.
Skills/Competencies
Soft Skills:
- Decision making
- Communication
- Project management
- Innovation
- Leadership
- Teamwork skills
- Problem-solving skills
Technical Skills:
- PCB assembly build processes
- SMT process
- Knowledge of PCBA manufacturing
- PTH knowledge
- Statistical process control
The expected pay rate for this position is $115,000.00 - $125,000.00 depending on specific skills and work experience.
About Company
Careers at USI
We're Looking for YoU!
Apply Online
USI is a team of more than 3,300 dedicated, experienced and innovative professionals in nearly 100 offices across the United States.
We are only as good as our people, and that is why we are highly selective in choosing new members for our team.
USI looks for individuals who:
- Have a passion to deliver exceptional client service
- Are self-motivated with a continuous desire to learn
- Are problem solvers who insist on finding ways to get it done – right
- Are team oriented and seek to collaborate with a diverse set of colleagues
- Are accomplished and seek excellence in themselves and to be a part of something exceptional
USI has many exciting and highly rewarding Career Opportunities. Apply Online Today!
USI Insurance Services is an equal opportunity employer.
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