Role Overview
SME - AOI & AXI is responsible for overseeing, optimizing & continuously improving processes to ensure on-time manufacturing with high quality of all ISP Products. Also to handle end to end machine setup , programming , Optimization , defect analysis , yield improvement and technical leadership across production lines.
The role is accountable for process yield, reliability, cost saving while building strong cross functional alignment with NPI & TD, equipment, quality and customer teams.
Key Responsibilities
- Technology & Process Setup
- Define and maintain all process windows, control plans & CTQ across all products of AOI & AXI machines.
- Setup, Operate, Programming & Optimizing AOI / AXI machines.
- Continuous program improvement to enhance FPY
- Conduct DOE & Process validation for new products and materials.
- Create & modify machine programs using online/offline SW. Component Library Creation & Lighting Parameter Optimization
- Machine Calibration and lightning optimization
- SPI & AOI Correlation analysis.
- Develop, debug and optimize AOI Programs for (SMT PCB assemblies, Through hole assemblies , BGA , QFN , Fine pitch components)
- Implement golden board strategy
- Detail AOI algorithm understanding ( 2D & 3D Inspection )
- New Model Readiness
- Develop & Maintain Process documentation, WIs & SOPs (AOI & AXI)
- All new models trail pre-readiness (EVT/ DVT / PVT) , new model trail activities including trial builds & process validation.
- Load & verify machine programs for New Product Trail.
- Conduct First Article Inspection.
- Partner with NPI, TDG to ensure DFMEA and PFMEA of AOI & AXI.
- Ensure proper solder paste reflow per component and PCB design requirements
- Ensure smooth technology transfer from development to production.
- Own ramp-up metrics: yield learning curve, cycle time, scrap reduction.
- Quality Excellence
- Accountable for first pass yield, final yield and field reliability.
- Lead root cause analysis for yield excursions using AOI , AXI data , charts , Yield Trends ,FMEA, DOE and failure analysis.
- Monitor False Call Rate , DPM & FPY , production yield , defect rates , cycle time and implement corrective / preventive actions.
- Perform Pareto analysis , Collaborate with Quality , NPI & Customer to resolve manufacturing & Quality issues.
- Partner with Quality team to address customer returns, audits and escalations.
- Maintain Process documentation & Production reports.
- Drive RCA for recurring defects
- Operational Excellence & Cost Optimization
- Own cost of ownership and productivity improvement initiatives.
- Drive Cycle time and line balancing improvements.
- Lead process development , validation & continuous improvement initiatives ( Kaizen , Poka yoke , Lean Manufacturing )
- To ensure Proper line setup , programming , Program version management ( AOI & AXI )
- To ensure compliance with ESD , Safety& IPC standards.
- Minimize downtime & improve machine utilization.
- Lead Cross functional improvement projects.
- Reduce false calls and escape defects
- Customer & Stakeholder Engagement
- Serve as a technical team member for customers on PCBA Process Topics.
- Will be technical team member for customer reviews, technology discussions and risk mitigation plans.
Key Deliverables & KPI
- First Pass Yield , RTY and Reliability Performance
- Productivity Improvement , Production Target Vs Actual Achievement
- Cost Optimization
- Customer satisfaction and Audit outcomes.
- Line Downtime Reduction
- Program Optimization Cycle Time
Required Qualifications
- Bachelor in related Engineering Discipline (Electronics /Electrical Engineering)
- 10-12 years hands on experience in SMT industry in a similar role (AOI & AXI )
- Experience in high volume manufacturing environment.
- Hands on knowledge of AOI & AXI machines ( Vitrox / Viscom / TRI / Kohyoung / Omron / Cyberoptics )
- Deep Understanding in defect classification ( Solder Bridge , Insufficient Solder , Tombstoning , Missing , Polarity Errors , Lifted Leads etc )
- Proficiency in root cause analysis & problem solving tools ( 8D , 5 why , DOE )
- Strong knowledge of SMT Process Flow ( Specially in SPI & IPC standards IPC-A-610 )
- CAD , Gerber File Handling & Image Processing Fundamentals
