Staff NPI Engineer (PCBA)

Staff NPI Engineer (PCBA) OUR MISSION SPAN IS ENABLING ELECTRIFICATION FOR ALL ⚡ We are a mission-driven company designing, building, and deploying products that electrify the built environment, reduce carbon emissions, and slow the effects of climate change. - Decarbonization is the process to reduce or remove greenhouse gas emissions, especially carbon dioxide, from entering our atmosphere. - Electrification is the process of replacing fossil fuel appliances that run on gas or oil with all-electric upgrades for a cleaner way to power our lives. AT SPAN, WE BELIEVE IN: - Enabling homes and vehicles powered by clean energy - Making electrification upgrades possible - Building more resilient homes with reliable backup - Designing a flexible and distributed electrical grid THE ROLE SPAN is looking for a Staff NPI (New Product Introduction) Engineer – PCBA to lead and execute the design transfer of our electronics hardware into production. The Staff NPI Engineer will bring deep expertise in PCBA manufacturing, SMT processes, and electronic assembly/test development. This role will own the technical interface with our contract manufacturers (CMs), ensuring robust processes for high-yield, scalable, and cost-effective builds. As the bridge between design and manufacturing, you will work cross-functionally with hardware design, test, manufacturing, and quality teams to drive smooth product introductions, ensure DFM/DFT readiness, and establish world-class manufacturing practices for our PCBAs and electronics modules. This position reports directly to our Director of Manufacturing Engineering and is part of the Supply Chain & Manufacturing (SCM) organization. Responsibilities - Lead the NPI process for PCBAs and electronics subassemblies, from prototype to high-volume manufacturing. - Apply DFx principles (DFM, DFT, DFQ, DFR, DFC) to electronic designs to ensure robust manufacturability, test coverage, and quality. - Partner with design engineers to review Gerbers/ODB++, schematics, and layouts for manufacturability and testability. - Define and implement PCBA test strategy (ICT, FCT, boundary scan, functional test fixtures) in collaboration with hardware and test engineering. - Drive SMT line qualifications, reflow profile validation, selective soldering, AOI/X-ray coverage, conformal coating and other PCBA processes. - Investigate and resolve issues with new designs and prototypes through assembly, testing, and system integration. - Own technical deliverables for CM onboarding, including process requirements, yield targets, test coverage, and quality control plans. - Identify and qualify quick-turn vendors to support prototype and early build activities, ensuring rapid iterations and feedback into design. - Develop and implement second-sourcing strategies to drive cost reduction and ensure supply continuity for critical components and processes. - Create, review, and submit engineering change orders (ECOs) to release design and process changes to improve manufacturability/serviceability. - Evaluate technical readiness before release and conduct Technical Readiness (TR) reviews with cross-functional teams. - Conduct BOM risk assessment, component testing, second sourcing, and manage Product Change Notifications (PCN) and qualifications. - Improve manufacturing operations to enhance efficiency, consistency, and cost-effectiveness while ensuring high product quality. - Generate and maintain manufacturing documentation (BOMs, ECOs, test procedures, visual aids, specifications). - Drive value engineering and cost reduction activities to optimize product lifecycle costs. - Travel to CM sites (~25–40%) for builds, process qualifications, and troubleshooting. ABOUT YOU Required Qualifications We are seeking a highly capable New Product Introduction Engineer who has: - BS or MS in Electrical Engineering, Electronics Engineering, Manufacturing Engineering, or equivalent discipline. - 8+ years of experience ... (truncated, view full listing at source)