Process Engineer - Circuit Card

Job Description
BAE Systems is seeking a Process Engineer to support Circuit Card Assembly (CCA) manufacturing operations for high-reliability aerospace and defense electronics.
This role is responsible for developing, optimizing, and sustaining manufacturing processes across CCA process and conformal coating operations. The Process Engineer will support process improvements, yield enhancement, defect reduction, and equipment performance, while contributing to New Product Introduction (NPI) and Non-Recurring Engineering (NRE) builds. This position requires strong collaboration with Operations, Quality, Maintenance, and Program teams to ensure compliance with AS9100 and IPC standards.
Job Duties

• Support daily manufacturing operations for CCA assembly and conformal coating
• processes.
• Monitor and maintain process performance for: conformal coating systems (manual, automated and selective, masking, curing, and inspection)
• Troubleshoot process and equipment issues using root cause analysis and corrective actions.
• Assist in developing and optimizing process parameters, recipes, and work instructions for coating and underfill processes.
• Support Statistical Process Control (SPC) initiatives by collecting and analyzing process data.
• Participate in yield improvement and defect reduction efforts.
• Support NPI activities, including prototype builds, process setup, coating trials, and DFM reviews.
• Assist with NRE builds, including new process introduction, and early production support.
• Support equipment qualification and validation activities (IQ/OQ/PQ) for conformal coating systems.
• Work with Quality Engineering to ensure compliance with AS9100, IPC-A-610, J-STD-001, and coating standards (e.g., IPC-CC-830 where applicable).
• Collaborate with Maintenance teams to improve equipment uptime.
• Maintain and update process documentation, including method sheets, PQP's, PFMEA's, control plans, and process flows.
• Participate in continuous improvement initiatives to improve efficiency, reduce waste, and lower manufacturing costs.
• Follow and support safety requirements, including LOTO procedures, chemical handling, and Job Safety Analysis (JSA)

Key Responsibilities

• Process Support & Optimization
• Support process development and optimization for SMT, SPI, AOI, reflow, and Wash operations
• Assist in improving process capability (Cp/Cpk) and yield performance
• Monitor process trends and support corrective actions
• Equipment & Process Control
• Support operation and optimization of: Conformal Coating processes
• Assist with process validation and equipment qualification activities
• Ensure process controls are maintained and followed
• NPI & NRE Support
• Assist in developing manufacturing processes for new products and coating requirements
• Help transition products from development to production
• Cross-Functional Collaboration
• Work with Operations, Quality, Maintenance, Engineering, and SHE teams
• Support production readiness and issue resolution
• Communication of process issues and improvement opportunities.

Required Education, Experience, & Skills

• Bachelor's degree in engineering (Manufacturing, Mechanical, Electrical, or related field)
• 2-5 years of experience in electronics manufacturing.
• Basic understanding of CCA assembly processes
• Knowledge of IPC-A-610 and J-STD-001 standards
• Familiarity with AS9100 quality systems
• Experience supporting NPI or development builds
• Strong problem-solving and analytical skills
• Ability to work in a fast-paced manufacturing environment

Preferred Education, Experience, & Skills

• Experience with SMT, SPI, AOI, reflow ovens, inline wash
• Familiarity with SPC (Statistical Process Control)
• Knowledge of IPC-CC-830 coating standards
• Experience in aerospace or defense manufacturing
• Lean Manufacturing or Six Sigma training (Green Belt preferred)

Pay Information
Full-Time Salary Range: $79365 - $134921
Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.
Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics.
About BAE Systems Electronic Systems
BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.
Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.
This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.