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 in NPI and PCBA manufacturing engineering - Deep knowledge of SMT processes, reflow soldering, wave/selective soldering, conformal coating, and in-circuit/functional test methods. - Hands-on experience with DFM/DFT tools, Gerber/ODB++ analysis, and PCBA CAD data review. - Proficiency in DFx principles: DFM, DFT, DFQ, DFR, DFC. - Strong knowledge of complex system-level debugging and root cause analysis. - Expertise in ECO, BOM, and deviation processes. - Knowledge of manufacturing, test, quality, and reliability best practices. - Ability to establish technical direction through the investigation and evaluation of new manufacturing technologies. - Strong working knowledge of industry manufacturing standards such as IPC and JEDEC. - Experience with process development, characterization, and pFMEA. Bonus Qualifications - Experience with automation technologies and robotics in manufacturing processes to improve efficiency and scalability. - Six Sigma Black Belt, or Lean Manufacturing certification. - Proven track record driving PCBA NPI strategy at a fast-growing hardware company. LIFE AT SPAN Headquartered in San Francisco’s vibrant SoMa neighborhood, we are an eclectic group of creative thinkers who value open communication, teamwork, and a ‘make it happen’ approach to addressing complex challenges.  SPAN embraces diversity and equal opportunity in a serious way. We are committed to building a team that represents a variety of backgrounds, perspectives, and skills.  We’re hiring talented individuals who are driven by success and are passionate about shaping the future of renewable energy. If that sounds like you, we’d love for you to consider joining the rapidly growing team at SPAN. The Perks: ⚡ Competitive compensation + equity grants at a well-funded, venture-backed company ⚡ Comprehensive benefits: 100% employee premiums for base plans on medical, dental, vision with options for additional coverage.  Parental leave up to twenty four (24)  weeks depending on eligibility ⚡ Comfortable, sunny office space located near BART and Caltrain public transit ⚡ Strong focus on team building and company culture: Employee Resource Groups, monthly social events, SPANcakes recognition breakfast, lunch, and learns ⚡ Flexible hours, one holiday per month, and flexible time off   Interested in joining our team? Apply today and we’ll be in touch with the next steps!