Manufacturing & Process Development Engineer II

About the role

The opportunity is to join TE Connectivity's industry-leading Passive Optics organization as a Manufacturing Process Development Engineer. You will drive manufacturing excellence in optical connector termination processes, tackling complex challenges in high-precision fiber optic termination.

Responsibilities

• Engineer manufacturing process development & optimization
• Design and optimize end-to-end optical connector manufacturing processes, including fiber prep, termination, polishing, and testing
• Develop process flows, work instructions, and manufacturing specifications for single-mode and multi-mode optical assemblies
• Lead DFM reviews to ensure new designs meet volume, quality, yield, and cost goals
• Drive PFMEA activities to identify risks and implement preventive controls
• Create complete production documentation (process specs, control plans, WI, quality procedures)
• Prepare and qualify tools, fixtures, and equipment for precision optical termination
• Coordinate qualification documentation, reviews, and approvals
• Manage pilot runs for new products, resolving engineering issues and validating process capability
• Establish and track key manufacturing metrics (Cpk, yield, cycle time)
• Technical problem solving & continuous improvement
• Lead FACA/root-cause investigations for manufacturing issues
• Implement continuous improvement using TEOA tools for cost, yield, and cycle-time optimization
• Run Kaizen events to eliminate waste, improve throughput, and reduce changeovers
• Enhance equipment reliability, process durability, and spare-parts efficiency
• Improve safety via machine guarding, control reliability, and operator protection initiatives
• Train and mentor operators and technicians in optical termination methods and quality practices
• Develop and deliver technical training on fiber handling, termination, inspection, and troubleshooting
• Implement competency assessments and certification programs
• Build mentorship programs to support skill development and knowledge transfer
• Update routing, cycle times, and parameters after process changes
• Optimize material flow, workspace layout, and personnel movement to reduce waste
• Support CapEx/OpEx decisions through cost, capability, and vendor analysis
• Integrate test systems, automation equipment, and MES for smooth production operations
• Develop technology roadmaps for next-generation optical connector manufacturing
• Innovate new processes for advanced connectors (expanded beam, ganged ferrules, high-density systems)
• Define automation strategies including robotic handling, automated polishing, and AI-based inspection
• Drive Industry 4.0 initiatives using IoT, predictive maintenance, and manufacturing analytics

Qualifications

• Education: BS in Manufacturing, Mechanical, Industrial Engineering, or related field
• Experience: 2–5 years in manufacturing process development, ideally in precision assembly, fiber optics, or electronics
• Technical Skills: Hands-on experience with optical connector termination, fiber handling, precision processes, and SPC
• Process Knowledge: Strong foundation in Lean, Six Sigma, and continuous improvement
• Core Technical Competencies: Optical Manufacturing, Proficiency in fiber cleaving, polishing, inspection, and optical testing with tight tolerance control; Manufacturing Systems, Experience with precision equipment, automated assembly, process validation, and equipment qualification; Quality Engineering, Skilled with PFMEA, SPC, control plans, MSA, and quality assurance tools; Process Documentation, Able to create clear process specs, work instructions, training content, and qualification protocols; Data & Statistics, Experience with statistical tools (e.g., Minitab, JMP) and capability analysis
• Specialized Knowledge: Fiber Optics, Expertise in single-mode/multi-mode handling, end-face prep, polishing, and testing; Precision Assembly, Strong understanding of high-precision mechanical assembly, alignment, and dimensional control; Supplier/CM Management, Experience with tech transfers, supplier qualification, and contract manufacturing; Automation & Robotics, Familiarity with robotics, vision systems, automated test, and process control systems; Lean & Six Sigma, Green Belt or higher; experienced in Kaizen and waste-reduction methods; Process Control, Proven ability in SPC implementation, MSA, and capability studies
• Software: Experience with simulation tools, CAD, MES, and ERP systems
• Standards Knowledge: Familiarity with ISO 9001, TS 16949, and optical standards (IEC, TIA/EIA)

Skills

• Problem Solving: Strong analytical and root-cause-analysis abilities
• Project Management: Skilled in managing cross-functional projects and meeting aggressive deadlines
• Communication: Able to present technical concepts clearly across all organizational levels
• Leadership: Experience leading FACA efforts, improvement initiatives, and mentoring technical staff

Benefits

A comprehensive benefits package including health insurance, 401(k), disability, life insurance, employee stock purchase plan, paid time off and voluntary benefits.