The Manufacturing Design Engineering (MDE) Team evaluates advanced manufacturing technologies and identifies scalable supply chain and process solutions that allow Technical Operations to bring next-generation consumer hardware products to market.
We are seeking a Mechanical Manufacturing Design Engineer (MDE) with deep technical expertise in Tier-II mechanical secondary operations, surface finishing, and assembly processes. In this role, you will bridge the gap between engineering design (PD/ID) and volume operations, defining scalable process flows, qualifying fixtures and automation, and driving supplier technical execution from early NPI prototyping through mass production.
The ideal candidate possesses demonstrated hands-on process engineering capability, understands the physics of materials and secondary operations, and can independently influence cross-functional decisions to balance design intent, cosmetic quality, high yields, and cost-effectiveness.
Responsibilities
- XFN Collaboration with Hardware Engineering (PD / ID):
- Serve as the primary manufacturing operations DRI for Tier-II secondary processes (post-forming/post-molding), guiding equipment selection, material compatibility, process parameters, and qualification frameworks to ensure cost-effective, high-volume
- manufacturability
- Evaluate critical part geometries, review vendor DFM, and recommend
- specification/tolerance adjustments to improve process capability ($C\_p / C\_{pk}$) and yield
- Lead exploration and benchmarking of novel secondary manufacturing and surface-finishing technologies during early NPI phases
- Secondary Process and Operational Ownership:
- Define and drive end-to-end secondary process flows, including precision CNC machining, bonding/dispensing, welding, heat staking, lamination, and cosmetic surface finishing (PVD, anodizing, painting, coating, polishing)
- Review, qualify, and optimize assembly and machining fixtures, inspection nests, and semi-automated/automated secondary equipment at supplier sites
- Establish and maintain the Manufacturing & In-Process Plan (MIP) with Tier-II suppliers across all build milestones (Proto/EVT/DVT/PVT/MP)
- Partner with SQE, Tooling, and ID to align on cosmetic and dimensional boundary samples, inspection protocols, and visual/functional yield ramp standards
- Commercial & Operational Strategy:
- Partner with Global Supply Management (GSM) to evaluate and select Tier-II manufacturing partners across APAC, assessing supplier technical competence, equipment capability, and line readiness
- Build technical proposals during conceptual NPI stages, providing process flow architecture, cycle-time modeling, throughput calculations, and cost-of-manufacturing analyses
- Present technical feasibility, operational trade-offs, and readiness roadmaps at core team reviews to secure cross-functional and executive alignment
- Supplier Capability & Lean Manufacturing:
- Drive suppliers to implement Lean manufacturing principles, optimize their tact and cycle time, reduce line touchpoints, and implement robust in-line process controls
- Design and execute structured Design of Experiments (DOEs) to systematically address root causes, resolve yield bottlenecks, and elevate supplier process maturity prior to ramp
Qualifications
- Education: Bachelor’s or Master’s degree in Mechanical Engineering, Manufacturing Engineering, Materials Science, or a related discipline
- Experience: 5+ years of hands-on experience in mechanical manufacturing process engineering, NPI bring-up, and technical problem-solving within the consumer electronics or precision
- hardware industry
- Secondary Process Mastery: Deep technical and hands-on experience across multiple mechanical secondary operations: Machining & Fabrication: Precision CNC machining (fixtures, cutter pathing/tooling) selection, multi-axis machining); Joining & Assembly: Ultrasonic welding, laser welding, structural adhesives, glue dispensing, and heat staking; Surface Finishing & Treatment: Anodization, PVD, painting/spray coating, pad printing, sandblasting, and precision polishing; Converting & Softgoods/Films: Die-cutting, PSA lamination, fabric wrapping, and thermoforming
- Fixture & Automation Understanding: Hands-on experience developing and qualifying precision fixtures, vacuum nests, and automated/semi-automated stations for small mechanical
- parts and sub-assemblies
- Statistical & Quality Engineering: Experience applying statistical process control methods; proficient in using JMP, Minitab, or Python/Excel to analyze DOE data, FAI, and SPC/Cpk metrics
- Vendor Management: Proven track record of managing and technical-coaching Tier II hardware suppliers in APAC regions
- Communication & Location: Fluent in written and verbal English and Mandarin, as the role requires direct technical coaching and daily communication with Tier-II suppliers in Mainland China; with the ability to travel frequently to supplier sites Experience adhering to and implementing responsible, ethical AI practices (e.g., risk assessment, bias mitigation, quality and accuracy reviews)
- Advanced Material & Structural Joining: Experience with specialized structural bonding, micro-screwing, thermal staking, ultrasonic/laser welding, and automated glue dispensing across mixed materials (metals, engineered plastics, and softgoods)
- Demonstrated ability to integrate AI tools to optimize/redesign workflows and drive measurable impact (e.g., efficiency gains, quality improvements)
- DFX / DFA Mastery: Experience conducting Design for Assembly (DFA) and Design for Manufacturing (DFM) reviews with Product Design (PD) early in NPI—identifying assembly interferences, optimizing datum schemes, simplifying part stacking, and minimizing manual assembly steps
- Demonstrated ongoing AI skill development (e.g., prompt/context engineering, agent orchestration) and staying current with emerging AI technologies
- Precision Small-Part Automation & Fixturing: Proven track record in designing, qualifying, and scaling high-precision automated assembly stations, robotic pick-and-place, vision-guided alignment, and custom assembly nests for micro/miniature components
- Assembly Process Development: Extensive experience in assembly line bring-up, line balancing, and mass production ramp for high-volume consumer electronics or wearable devices
- Critical Module Integration: Hands-on experience developing assembly and calibration processes for sensitive modules such as camera, audio, display, optical-mechanical, and sensor sub-assemblies
- Lean Assembly Line Design: Practical background in takt time optimization, operator ergonomics, poka-yoke (error-proofing) mechanism design, and Six Sigma/Lean manufacturing methodologies to eliminate bottlenecks and minimize scrap