Career Overview: What I Do As a Process Engineer
When a device works well, you probably give little thought to how it was made, let alone how thousands and thousands of devices were made. There is a lot of public attention to design, but figuring out how to reproduce something to scale is an engineering feat in and of itself.
To learn a little about the work that goes into manufacturing, we spoke to a young engineer who previously worked for a commercial electronics manufacturer and is now creating electronics that will be sent into space. (Unsurprisingly, the quality standards for space travel are a little stricter!)
First, tell us a little about your current position and how long you have been in it. In general, what does a process engineer like you do?
I’m an electronics engineer for a large government contractor for their space division. I’m new to this game: I worked for a small commercial electronics manufacturer for less than a year, then I jumped at the opportunity at this current company, and I’ve been here for half a year now. I’m not an expert, but I hope this helps anyone interested in this area.
Process engineers maintain a production workshop, which includes the following:
- From engineering drawings, process engineers create plans and instructions detailing how to build equipment with tools and equipment spread out on the floor. Think of LEGO instructions, but much more complex.
- Process engineers also work with floor support. Manufacturers (hourly workers) who work with equipment (our products) contact us with any questions or concerns they may have: problems with their equipment, problems with equipment, questions about work instructions, basically anything … Technological engineers solve floor problems to keep the product moving.
- Process engineers program all equipment used to operate the equipment. This is not real programming / coding, but simply telling the machine what to do and saving those settings and programmed actions. Most simpler automation tools take X, Y, and Z coordinates and perform specific actions at each point (for example, move the nozzle here, spray here, move the nozzle up to avoid knocking parts, etc.).
- We are also looking for ways to improve processes. Automation is the king of manufacturing. Machines usually don’t go wrong (although I had several conveyor boards …)
- And we do an amazing amount of paperwork.
- We find, research and test / test new flooring machines and equipment. I had the opportunity, for example, to fly to the company to test a completely new car that interested us.
- We are responsible for finding new equipment, proving that it will benefit the company through a ROI analysis (will we get our investment back?), And confirming that the machine is as good as they claim.
What prompted you to choose your career path? How did you get a job? What kind of education and experience did you need?
I studied industrial engineering in college. It was difficult for me to find a job and I took a software job. I felt like I was wasting my degree, so after a year and a half, I took a job manufacturing commercial electronics. I had a friend who worked there, so he sent my resume. I learned about opening a contract with a government contractor through another friend and sent my resume to his friend at that company. Somehow I got the job … very lucky.
Connections and networks are surprisingly helpful. Don’t underestimate them!
Do you need any licenses or certificates?
No, but in case you’re wondering, I passed the Fundamentals of Engineering (FE) exam. Not necessarily, but I’m sure it didn’t hurt.
What’s your average uptime?
Average working time from 9 to 12+. Production works in shifts. There are 24 hours in a day, and you can be sure that most manufacturers intend to use as many watches as possible.
1st shift from 6 am to 3 pm, which is surprisingly great. 2nd shift from 15.00 to 12.00. Some companies use a third shift from 22:00 to 6:00. 2nd and 3rd shifts pay a little more because you are sacrificing your social life. Oh, and there is exit lighting. The production can be tedious, but you will gain a ton of experience.
What are you doing differently from your colleagues or colleagues in the same profession? What are they doing instead?
In electronics manufacturing, commerce and space are completely different fields. When I was in advertising, we focused on quantity. We aimed to increase productivity by reducing cycle times in minutes or seconds because we were producing hundreds of boards per day. In the production of space electronics, things are going slower and much more deliberately. Quality comes first.
What’s the worst part of a job and how do you deal with it?
Manufacturing commercial electronics is a tricky business, especially since almost everything has already been transported to China. There was little money in a small commercial company. I didn’t always have the tools I needed to get the job done. The request for new equipment and tools was associated with a lot of bureaucracy. I hate red tape.
Weekend lighting sucks, but at least it’s a chilly day where you provide a little support and catch up with paperwork.
What is the most enjoyable part of the job?
I help create things that go into space!
In my last job, I enjoyed helping manufacturers and solving problems the most. I’ve been close to many of these guys. These are some of the most hardworking people I have met.
What advice would you give to those who want to become your profession?
Question the status quo, especially if the answer is “this is how we always did it.” Look for ways to automate processes. Explore IPC [a set of standards for manufacturing and assembly of electronics] for commercial and J-STD specifications for space; they dictate the standards for printed circuit boards. It should be remembered about Six Sigma and other mantras efficiency.
This interview has been edited for clarity.