Manufacturing/New Product Introduction (NPI) Engineer

Summary:

The Manufacturing / New Product Introduction (NPI) Engineer is responsible for successfully transitioning new connector, cable assembly, wire harness, and electromechanical products from design through production while ensuring manufacturability, quality, cost, and delivery objectives are achieved. This position serves as the technical bridge between customers, design engineering, operations, quality, supply chain, and manufacturing to ensure a seamless product launch and scalable production process.

The NPI Engineer leads Design for Manufacturability (DFM), process development, tooling selection, work instruction creation, validation testing, and production readiness for products supporting hazardous industrial and energy markets including oil & gas, mining, offshore, renewable energy, power generation, rail, heavy equipment, marine, and industrial automation.

This position plays a key role in supporting Amphenol’s commitment to delivering highly reliable interconnect solutions for harsh environment applications requiring superior performance, durability, and quality.

Knowledge/Skills:

• Strong understanding of connector manufacturing, cable assembly, wire harness, and electromechanical assembly processes.
• Working knowledge of CNC machining and precision component manufacturing.
• Experience with hazardous environment connector applications including ruggedized, sealed, EMI/RFI shielded, high-power, fiber optic, and hybrid connector systems.
• Strong understanding of Design for Manufacturability (DFM), Design for Assembly (DFA), and concurrent engineering principles.
• Knowledge of IPC/WHMA-A-620 workmanship standards and IPC-A-610 preferred.
• Experience creating manufacturing documentation including BOMs, routers, work instructions, process flows, PFMEA, and Control Plans.
• Strong understanding of Lean Manufacturing and Continuous Improvement methodologies.
• Experience performing Root Cause Analysis using 8D, 5 Why, Fishbone, and FMEA.
• Strong mechanical aptitude with knowledge of crimping, soldering, overmolding, potting, sealing, and cable termination processes.
• Experience with ERP/MRP systems and Engineering Change Order (ECO) management.
• Excellent written and verbal communication skills.
• Ability to manage multiple complex projects simultaneously.
• Strong analytical and organizational skills.

Qualifications - Education/Experience:

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Electrical Engineering, or related technical discipline.
• Minimum 5 years of engineering experience within connector manufacturing, cable assemblies, wire harnesses, electromechanical products, or industrial manufacturing.
• Experience supporting New Product Introduction (NPI) from concept through production.
• Experience with precision manufacturing including CNC machining preferred.
• Experience supporting products used in harsh environment or hazardous industrial applications preferred.
• Working knowledge of ISO 9001 Quality Management Systems.
• Experience with IPC/WHMA-A-620 preferred.
• CAD experience utilizing SolidWorks, Creo, AutoCAD, or equivalent preferred.
• Experience supporting low-volume/high-mix manufacturing environments.
• Knowledge of UL, CSA, CE, ATEX, IECEx, NEC, or other hazardous location product requirements is highly desirable.
• Strong proficiency with Microsoft Office and ERP software.

Duties/Responsibilities:

New Product Introduction (NPI)

• Lead new product introductions from engineering release through successful production launch.
• Review customer drawings, specifications, and technical requirements for manufacturability.
• Develop manufacturing processes supporting scalable production and future business growth.
• Create manufacturing routings, Bills of Materials (BOMs), process documentation, and work instructions.
• Coordinate prototype builds and pilot production activities.
• Manage Engineering Change Orders (ECOs) throughout the product lifecycle.
• Develop project timelines ensuring successful product launches.

Manufacturing Engineering

• Design and improve manufacturing processes for connector assembly, cable assembly, wire harness production, and precision machined components.
• Develop tooling, fixtures, assembly aids, and manufacturing equipment.
• Improve manufacturing efficiency through process optimization and automation.
• Reduce manufacturing cycle times while maintaining world-class quality.
• Support CNC machining process improvements and production optimization.
• Standardize manufacturing methods across product families.

Design for Manufacturability (DFM)

• Participate in design reviews with customers and product engineering teams.
• Recommend design improvements that enhance manufacturability, reliability, quality, and cost.
• Evaluate tolerance stack-ups and assembly methods.
• Support value engineering initiatives to improve product cost and performance.

Product Validation

• Develop manufacturing validation plans.
• Create verification and validation protocols.
• Coordinate qualification testing for new products.
• Analyze validation data and prepare engineering reports.
• Support First Article Inspection (FAI) and PPAP activities where required.

Quality & Continuous Improvement

• Partner with Quality Engineering to establish Control Plans and PFMEAs.
• Investigate manufacturing and product quality issues.
• Lead Root Cause Analysis and corrective actions.
• Implement Lean Manufacturing and Kaizen initiatives.
• Drive continuous improvement projects reducing scrap, rework, and production lead time.

Customer & Technical Support

• Support customer technical reviews and engineering meetings.
• Provide manufacturing input during customer design reviews.
• Support production transfers between facilities.
• Assist Sales with technical evaluations and manufacturability assessments during quotation activities.

Documentation

• Develop and maintain:

- Manufacturing Work Instructions

- Process Flow Diagrams

- Assembly Procedures

- Inspection Procedures

- Test Procedures

- Standard Operating Procedures (SOPs)

- PFMEAs

- Control Plans

- Tooling Documentation

- Validation Reports

- Engineering Change Documentation

Innovation & Automation

• Identify automation opportunities within cable assembly and connector manufacturing.
• Evaluate emerging manufacturing technologies including automated crimping, robotic assembly, vision inspection, laser marking, automated testing, and Industry 4.0 solutions.
• Support digital manufacturing initiatives utilizing real-time production data and analytics.
• Recommend capital equipment investments improving productivity and manufacturing scalability.

Preferred Industry Experience:

Experience with products supporting:

• Oil & Gas Exploration
• Offshore Energy
• Renewable Energy
• Mining Equipment
• Industrial Automation
• Power Generation
• Rail Transportation
• Heavy Equipment
• Marine
• Hazardous Locations
• Process Control Systems

Experience with interconnect solutions including:

• Circular Connectors
• MIL-Spec Connectors
• Rugged Industrial Connectors
• High-Speed Data Connectors
• Fiber Optic Assemblies
• Power Connectors
• Hybrid Connectors
• Overmolded Cable Assemblies
• Wire Harnesses
• EMI/RFI Shielded Assemblies

Benefits:

• Medical, Dental, and Vision Insurance
• Company-Paid Life Insurance
• Short-Term and Long-Term Disability
• 401(k) Retirement Plan with Company Match
• Paid Time Off (PTO) and paid company holidays
• Employee Assistance Program (EAP)
• Professional Development and Training Opportunities

Physical/Environmental Requirements:

• Office environment with frequent presence on the manufacturing floor.
• Regular interaction with production equipment and manufacturing personnel.
• Occasional lifting of up to 30 pounds.
• Domestic and occasional international travel to customer locations, supplier facilities, and manufacturing sites.
• The physical requirements described here are representative of those necessary to successfully perform the essential functions of this position. Reasonable accommodations may be made to enable qualified individuals with disabilities to perform these functions.