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About the Role

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.

Responsibilities

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).
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.
Support operation and optimization of Conformal Coating processes.
Assist with process validation and equipment qualification activities.
Ensure process controls are maintained and followed.
Assist in developing manufacturing processes for new products and coating requirements.
Help transition products from development to production.
Work with Operations, Quality, Maintenance, Engineering, and SHE teams.
Support production readiness and issue resolution.
Communication of process issues and improvement opportunities.

Requirements

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

Skills

SMT
SPI
AOI
Reflow ovens
Inline wash
Statistical Process Control (SPC)
IPC-CC-830 coating standards
Aerospace manufacturing
Defense manufacturing
Lean Manufacturing
Six Sigma
Root cause analysis
Corrective actions
Process parameters
Recipes
Work instructions
Statistical Process Control (SPC)
NPI
NRE
Equipment qualification
Process validation
AS9100
IPC-A-610
J-STD-001
IPC-CC-830
Continuous improvement
Safety requirements
LOTO procedures
Chemical handling
Job Safety Analysis (JSA)
Process capability (Cp/Cpk)
Yield performance
Conformal Coating processes
Process controls
Manufacturing processes
Product development
Production readiness
Issue resolution

Work Type

Full-Time

Experience Level

2-5 years

Education Level

Bachelor's degree in engineering (Manufacturing, Mechanical, Electrical, or related field)

Salary/Compensations

$79365 - $134921

Benefits

Health, dental, and vision insurance
Health savings accounts
401(k) savings plan
Disability coverage
Life and accident insurance
Employee assistance program
Legal plan
Discounts on home, auto, and pet insurance
Paid time off
Paid holidays
Paid parental leave
Paid military leave
Paid bereavement leave
Paid federal and state sick leave
Company recognition program

About the Company

BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace and security company which delivers a full range of products and services for air, land and naval forces, as well as advanced electronics, security, information technology solutions and customer support services.
Improving the future and protecting lives is an ambitious mission, but it’s what we do at BAE Systems.
Working here means using your passion and ingenuity where it counts – defending national security with breakthrough technology, superior products, and intelligence solutions.
As you develop the latest technology and defend national security, you will continually hone your skills on a team—making a big impact on a global scale.
At BAE Systems, you’ll find a rewarding career that truly makes a difference.
Electronic Systems (ES) is the global innovator behind BAE Systems’ game-changing defense and commercial electronics.
Exploiting every electron, we push the limits of what is possible, giving our customers the edge and our employees opportunities to change the world.
Our products and capabilities can be found everywhere – from the depths of the ocean to the far reaches of space.
At our core are more than 14,000 highly talented Electronic Systems employees with the brightest minds in the industry, we make an impact – for our customers and the communities we serve.