PCB Process & Manufacturing Specialist

Location: Bangalore - Indraprastha, India

Thales is a global technology leader trusted by governments, institutions, and enterprises to tackle their most demanding challenges. From quantum applications and artificial intelligence to cybersecurity and 6G innovation, our solutions empower critical decisions rooted in human intelligence. Operating at the forefront of aerospace and space, cybersecurity and digital identity, we’re driven by a mission to build a future we can all trust.

Present in India since 1953, Thales is headquartered in Noida and has other operational offices and sites spread across Delhi, Gurugram, Bengaluru and Mumbai, among others. Over 2200 employees are working with Thales and its joint ventures in India. Since the beginning, Thales has been playing an essential role in India’s growth story by sharing its technologies and expertise in Defence, Aerospace and Cyber & Digital sectors. Thales has two engineering competence centres in India - one in Noida focused on Cyber & Digital business, while the one in Bengaluru focuses on hardware, software and systems engineering capabilities for both the civil and defence sectors, serving global needs. The Group has also established an MRO (Maintenance, Repair & Overhaul) facility in Gurugram to provide comprehensive avionics maintenance and repair services to Indian airlines and support the growth of the local aviation industry.

Primary Purpose of the Role:
Thales is expanding its presence in India through the development of a Group Engineering Competence Centre (ECC), reinforcing its position as a leader in all its markets. Launching in early 2019 in Bengaluru, the ECC will expand Thales’ footprint in its core business areas and cement its long-standing relationship with India. Thales has an objective to expand industrial process engineering function in India ensuring remote engineering support to Thales Industry and preparing industrial footprint expansion in the region. Achieving a high level of maturity for our products in production is one of the major challenges of the Thales industry, both during the industrialization phase and throughout the product's life cycle.
This Job Description is for Industrial Process Engineering & the Role is PCB PROCESS & MANUFACTURING SPECIALIST.
The role is based in Bangalore and requires frequent travel to supplier sites across Bangalore and other locations within India and Asia.

Organization:
You will be part of the Industrial Process Engineering – Industrialization team, responsible for defining and managing manufacturing technologies for electronic boards, mechanical components, and related processes. The team supports all product life-cycle phases, bidding, development, and series production.

Key Responsibilities and Tasks:

Core Responsibilities
•Responsible for co-developing, qualifying, optimizing, printed circuit board (PCB) manufacturing processes with PCB Suppliers
•Work closely with PCB suppliers to ensure adherence to approved manufacturing processes, specifications, and quality requirements - Serve as the primary technical point of contact for PCB manufacturing processes with suppliers.
•Review, challenge, and validate supplier process documentation (process flows, control plans, PFMEA, work instructions) and ensure compliance with IPC standards, customer, and internal guidelines.
•Support resolution of manufacturing and quality issues during development and series production, including participation in supplier audits and on-site technical reviews.
•Drive continuous improvement initiatives with suppliers, including cost, quality, lead-time optimization, supplier qualification, and standardization of best practices across the supply base.
•Manage process evolution and technology upgrades.
NPI Activities (working with industrial architects and engineering teams)
Support New Product Introduction (NPI) and industrialization activities at supplier sites in following phases:
•R& T Phase:
o Collaborate with R&T teams to support industrialization activities, Manufacturing Readiness Level (MRL) maturity plans, and the introduction of emerging PCB technologies, materials, and processes.
• Bidding Phase:
o Evaluate and recommend PCB manufacturing processes based on risk assessments and supplier capability, including technical support during supplier selection.
o Contribute to supplier qualification by assessing process maturity and validating process–supplier combinations.
• Development Phase:
o Develop, execute and approve process qualification and APQP plans to confirm manufacturing readiness, including tooling, materials, and equipment capability.
o Conduct DFM/DFA reviews with internal design teams and suppliers and propose design optimizations to achieve target cost and manufacturability objectives.
o Lead supplier industrial reviews such as Production Readiness Reviews (PRR) and First Article Inspections (FAI).
Transfer & Series Production Activities (in coordination with Series Product Managers, Supplier Product Quality Managers, and Industrial Transfer Managers)
• Manage BTP (Build To Print) transfer by:
o Ensuring the supplier achieve technical capability (mastering of technological processes before transfer)
o Defining and monitoring test vehicles before transfer
o Leading and validating PRR & FAI
• Provide technological support for production, including defect analysis and expert intervention.
• Lead root cause analysis and drive corrective actions for manufacturing or assembly issues.
• Manage risk assessments and mitigation strategies throughout the project lifecycle.
• Manage process evolution and technology upgrades with subcontractors and relevant stakeholders
Cross-Functional Missions
• Develop and update technical standards within the PCB domain; participate in Thales Group-wide working groups.
• Suggest process and business tool improvements to enhance efficiency and quality.
• Ensure adherence to professional standards guaranteeing compliance with IPC, ISO, EN 9100, and other aerospace quality requirements.
Work closely with the France team to understand and benchmark processes, then collaborate with suppliers to implement and qualify those processes.

Major Challenges
• Ensure Supplier Quality Process Development meets global industrial plan & Timeline
• Work with multiple GBU’s/BL’s of France in a different Time Zone
• Work with multiple Suppliers/multiple projects in tandem for Process Qualification
• Continuously Develop the required technical skills (skilling-up) and capability by effective learning Opportunities
• Chance to work in an organization that is driving towards building a structured engineering footprint in line with Thales’ growth and competitiveness ambition
• Chance to be in contact with people having different cultural background from across the world
• A working environment that facilitates professional development through continuous learning, close collaboration within teams and a solution-oriented attitude Skills & Knowledge Required Technology Skills
• Strong knowledge of PCB fabrication and assembly processes (multilayer boards, flex and rigid-flex PCBs.)
• Familiarity with IPC standards and quality requirements
• Knowledge of materials, components, and supply chain relevant to PCB & PCBA.
• Familiar with EN9100 aerospace quality standards.
• Ability to read and interpret PCB drawings, Gerber files, and BOMs
• Expertise in inspection and analysis methods such as SEM (Scanning Electron Microscopy), X-rays, micro-sectioning, and destructive testing
• Additional Knowledge of PCBA (Printed Circuit Board Assembly) processes: SMT, through-hole, wave soldering, reflow soldering, and inspection techniques.

Quality Tools
• Knowledge & Hands on of APQP (Advanced Product Quality Planning) methodology.
• Experienced in problem-solving and root cause analysis techniques like PDCA, 8D, 5 Whys, Fishbone Analysis especially related to electronic board assembly technologies.

Soft Skills
• Learning & Proactive mindset with a continuous focus on improvement.
• Strong analytical, communication, interpersonal and problem-solving abilities.
• Dynamic and flexible, able to adapt to changing priorities.
• Analytical thinker with strong problem-solving skills and logical reasoning.
• Detail-oriented with a focus on quality and continuous improvement.
• Ability to work independently and manage multiple priorities.

Years of experience Required
• 8 to 10 years in printed circuit technologies, including 2+ years in PCB fabrication, process planning, and manufacturing.
• Experience including NPI and series production in In House & outsourced environments; aerospace experience preferred.

Educational Qualification Required
• Bachelor/Masters in Electronics Engineering Language • English • French basic knowledge is a plus

At Thales, we’re committed to fostering a workplace where respect, trust, collaboration, and passion drive everything we do. Here, you’ll feel empowered to bring your best self, thrive in a supportive culture, and love the work you do. Join us, and be part of a team reimagining technology to create solutions that truly make a difference – for a safer, greener, and more inclusive world.