Sr Process Engineer

About the role

As a Senior Process Engineer – Electronics Assembly at Honeywell Aerospace, you will develop, optimize, and sustain manufacturing processes for electronic assemblies, including microelectronic assembly (RF and waveguide), mechanical integration, and final system build. You will drive process capability, quality performance, cost reductions, and operational efficiency through data-driven problem solving, cross-functional collaboration, and technical leadership. This role reports directly to the Sr. Manufacturing Engineering Supervisor and is based at our Woburn, MA location on an on-site work schedule.

Responsibilities

• Lead development, qualification, and continuous improvement of electronics assembly processes (SMT, wave/selective solder, manual assembly, microwave hybrid assembly, conformal coating, testing, wire bonding, etc.).
• Define and maintain process parameters, work instructions, PFMEAs, control plans, and standard operating procedures.
• Specify, evaluate, and implement new production equipment, tooling, and automation to improve throughput, quality, and ergonomics.
• Drive root-cause investigations using structured problem-solving methodologies (8D, DMAIC, PFMEA updates).
• Analyze production data using Lean and Six Sigma to identify trends, process variation, and areas for improvement.
• Support NPI (New Product Introduction) activities, including DFM/A reviews, process design, and production readiness.
• Partner with Quality Engineering to resolve defects, reduce scrap/rework, and strengthen process controls.
• Train operators and technicians on new processes, equipment, and best practices.
• Lead or contribute to cost-reduction initiatives related to materials, processes, and yields.
• Ensure compliance with applicable standards (IPC A-610, J-STD-001, ISO 9001, AS9100, etc.).
• Act as the technical subject matter expert for electronics assembly processes.

Requirements

You must have:

• 7+ years of experience in electronics manufacturing, microelectronics assembly, or a related process engineering role.
• Strong knowledge of microelectronic assembly, soldering standards, IPC guidelines, and PCB manufacturing fundamentals.
• Hands-on experience with equipment such as pick and place machines, reflow ovens, AOI/AXI, wave/selective solder, auto bonding, and conformal coating.
• Demonstrated proficiency in process characterization, DOE, SPC, and data analysis.
• Proven experience leading cross-functional projects from concept to implementation.

We value:

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Electrical Engineering, Industrial Engineering, or a related field.
• Experience in aerospace, defense, or highly regulated manufacturing environments.
• Six Sigma Green or Black Belt certification.
• Experience with automation systems, robotics, or advanced manufacturing technologies.
• Knowledge of ERP/MRP systems (SAP, Oracle, etc.).
• Prior experience mentoring engineers or leading technical teams.

Benefits

• Comprehensive benefits package including employer-subsidized Medical, Dental, Vision, and Life Insurance.
• Short-Term and Long-Term Disability coverage.
• 401(k) match and retirement benefits.
• Flexible Spending Accounts and Health Savings Accounts.
• Employee Assistance Program (EAP) and Educational Assistance.
• Paid Time Off (vacation, personal business, sick time, and parental leave).
• 12 Paid Holidays.
• Parental Leave.

Pay

Competitive salary.

Due to compliance with U.S. export control laws and regulations, candidates must be a U.S. person, defined as a U.S. citizen, U.S. permanent resident, or have protected status in the U.S. under asylum or refugee status.