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The Senior Manufacturing Engineer will optimize PCBA/SMT processes, manage factory teams, apply DFX principles, and drive continuous improvement using Lean Six Sigma.
At WHOOP, we're on a mission to unlock human performance and healthspan. WHOOP empowers users to perform at a higher level through a deeper understanding of their bodies and daily lives.
As a Senior Manufacturing Engineer, PCBA/SMT, you will work cross-functionally with Electrical, Firmware, Mechanical, and Factory teams to develop PCB/A designs and optimize Surface Mount Technology (SMT) and PCBA assembly processes, support the manufacturing ramp, and ensure high quality and efficiency from prototype builds through full production and continuously improve mature manufacturing lines. You are experienced in DFX (Design for Manufacturability, Testability, Assembly, Cost), process design and validation, SMT equipment and fixture development, and are hands-on at the factory floor and are data driven.
RESPONSIBILITIES:
- Drive PCBA/SMT manufacturing readiness through collaborative process development, documentation, optimization, and validation for new product introductions.
- Tactically manage factory teams and partners to design/develop, qualify, and implement SMT and PCBA fixtures, tooling (stencils), and automation (underfill, routing, AOI) using data-driven decision making.
- Execute DFX principles during all phases of product development and mass production to optimize manufacturability, yield, and cost.
- Ensure process control and verification to meet all product specifications for electrical and mechanical performance.
- Apply Lean Six Sigma methodologies to drive continuous improvement in quality, efficiency, cycle time, and cost.
- Define and conduct Design of Experiments (DOE), Failure Analysis (FA), and structured problem-solving (DMAIC, 8D) to resolve manufacturing issues and implement corrective actions.
- Lead cross-functional efforts on rapid development cycles while evaluating options for optimal form, fit, function, and manufacturability of PCBAs.
- Provide clear project tracking, status updates, and risk mitigation reporting to stakeholders.
- Plan and coordinate parallel path strategies to address high-risk project milestones.
- Support vendor management, including technical guidance for contract manufacturers (CM) and joint development manufacturers (JDM).
- Willingness to travel up to 25% to domestic and international manufacturing locations.
QUALIFICATIONS:
- Bachelor’s Degree in Engineering, Manufacturing, or a related technical field.
- 5+ years of PCBA/SMT manufacturing experience, preferably in moderate to high-volume consumer electronics.
- Strong expertise with SMT processes including stencil printing, pick-and-place, reflow soldering, AOI/X-ray inspection, and manual/automated rework.
- Solid understanding of PCBA assembly challenges and miniaturization, spacing, solder joint quality, and common defect modes (e.g., tombstoning, solder voids, open circuits).
- Knowledge of DFM/DFT/DFX for PCB layouts and assembly processes.
- Hands-on experience qualifying and troubleshooting manufacturing processes and equipment on the factory floor.
- Familiarity with IPC standards (e.g., IPC-A-610) and GD&T principles for mechanical integration of PCBAs.
- Experience with SolidWorks or similar CAD software for fixture and tooling design.
- Strong organizational, multi-tasking, and time management skills.
- Demonstrated ability to communicate effectively across engineering, manufacturing, and supply chain teams, including external CM/JDM partners.
- Experience with ultrasonic welding, adhesives, and mechanical assembly is a plus (for products integrating electronics into enclosures).
This role is based in the WHOOP office located in Boston, MA. The successful candidate must be prepared to relocate if necessary to work out of the Boston, MA office.
Interested in the role, but don’t meet every qualification? We encourage you to still apply! At WHOOP, we believe there is much more to a candidate than what is written on paper, and we value character as much as experience. As we continue to build a diverse and inclusive environment, we encourage anyone who is interested in this role to apply.
WHOOP is an Equal Opportunity Employer and participates in E-verify to determine employment eligibility. It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.
Top Skills
Cad
Dfx
Ipc Standards
Lean Six Sigma
Pcba
Smt
Solidworks
WHOOP Boston, Massachusetts, USA Office
1 Kenmore Sq, Boston, MA, United States, 02215
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