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Process Engineer Staff - Regional Hand Solder & Rework SME

Plexus · IL · $97,900–$162,000 a year · Full time

Posted Sep 17, 2026 · We last checked this listing on Oct 6, 2026

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Likely interview questions for this role

Written from this job description, not a generic list. Each one notes what the interviewer is really checking.

About your past

Tell me about a solder defect problem you traced to its root cause.

What they are checking: Whether they investigate across materials, tools, training and design rather than blaming the operator.

Describe a time you reduced the amount of rework a line needed in the first place.

What they are checking: Whether they work upstream to prevent defects, which saves more than making rework faster.

How do you stay current on new solder materials, components and techniques?

What they are checking: Whether a staff-level expert keeps learning, since packaging and alloys keep changing.

What would you do

A site insists its own rework method is fine even though it doesn't match the regional standard. How do you handle it?

What they are checking: Whether they can persuade with data and respect local knowledge while still bringing sites into alignment.

A customer for a medical or aerospace product has limits on how many times a part can be reworked. How do you make sure the floor follows that?

What they are checking: Whether they build controls like traveler tracking into the process so customer limits are never missed.

How do you handle supporting several sites remotely when you can't be on every floor?

What they are checking: Whether they can lead from a distance with clear standards, local champions and regular check-ins.

About the work

As a regional subject matter expert for hand solder and rework, how would you raise and standardize capability across several sites?

What they are checking: Whether they can spread best practice across sites with different habits, not just be the best solderer in one building.

Which IPC standards do you rely on for hand solder and rework, and how do you apply them on the floor?

What they are checking: Whether they know IPC-A-610, J-STD-001 and IPC-7711/7721 in practice, not just by name.

Walk me through how you'd rework a fine-pitch or BGA component without damaging the board.

What they are checking: Whether they understand thermal profiles, pad damage risks and when rework should not be attempted at all.

How do you train and certify hand solder operators, and how do you know the training stuck?

What they are checking: Whether they verify skill over time with audits and data, not just certificates on the wall.

How do you choose soldering equipment, tips, flux and temperatures for different jobs?

What they are checking: Whether they understand how equipment and materials choices affect joint quality and component damage.

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The full job description

As published by Plexus.

About us: At Plexus, our vision is to help create the products that build a better world. Driven by a passion for excellence, we partner with leading Aerospace/Defense, Healthcare/Life Sciences and Industrial companies to design, manufacture and service some of the world’s most transformative products, including advanced surgical systems, diagnostic instruments, healthcare imaging equipment, mission critical aerospace systems, and electric vehicle (EV) charging solutions. Visit Plexus.com to learn more about our unwavering commitment to our vision. When we invest in our people, we invest in building a better world. With a vision rooted in the wellbeing and inclusive engagement of our team members, our customers, their end users and our communities, people are the heart of what we do and who we are. It is our values that unite us and guide us in everything that we do, including how we operate, behave and interact to foster a workplace where every team member feels valued and empowered to contribute their best. Our values include: Growing our People, Building Belonging, Innovating Responsibly, Delivering Excellence and Creating Customer Success. As a team member, you will engage in impactful work through global collaboration and the use of emerging technologies, join an inclusive culture where every team member is valued and working toward a greater purpose, and be empowered to reach your full potential through various development programs designed to accelerate your growth. Plexus offers a comprehensive benefits package designed to support team members' wellbeing, including medical, dental, and vision insurance, paid time off, retirement savings, and opportunities for professional development. We also prioritize work-life balance and offer a variety of perks to enhance the team member experience. For more information, visit our US benefits website at usbenefits.plexus.com . Our commitment to pay range transparency fosters an equitable workplace, where everyone can feel valued. The annual compensation range for this position is stated below. The salary offered within this range will be based upon the geographic location, work experience, education, licensure requirements and/or skill level. Salary Range: $97,900.00 - $162,000.00 Purpose Statement: The process engineer is responsible for providing technical expertise throughout the manufacturing process. This role involves offering guidance on best practices and equipment, optimizing production for efficiency and quality, training various teams, and supporting ongoing production activities. They also ensure the manufacturability of new products while adhering to standards and lead new product introduction processes. Key Job Accountabilities: • Regarded as a "go to" technical specialist, leader and mentor within their Manufacturing discipline; and/or regarded as a cross-discipline leader and mentor for product / process development, process improvement or troubleshooting within site/ region, as it applies to their role. • Serves as a technical and/or project team lead providing technical guidance/ training, controlling scope, schedule, budget and ensuring overall technical success on small to mid-size Plexus Manufacturing Processes, as it applies to their role. • Leads continuous improvement activities associated with their engineering discipline and/or project-level tools or processes, as it applies to their role. • Provides customer service leadership in project technical discussions, business continuity and new proposal creation. Education/Experience Qualifications: • Bachelor’s Degree with 6 or more years of related experience is preferred. An equivalent combination of education and/or experience will be considered. Other Qualifications: • A Subject Matter Expert (SME) in Hand Solder & Rework of Printed Circuit Board Assemblies (PCBA’s) • Knowledge of, and expertise in, IPC-7711/7721, IPC J-STD-001 (with Space/Military Addendum), & IPC-A-610 • Understanding of the behavioral differences between leaded (e.g., Sn63/Pb37) and lead-free alloys (e.g., SAC305), intermetallic compound (IMC) layer growth, and flux chemistry • Demonstrated ability to define the standards, select & qualify advanced tooling & equipment, and architect rework processes for high-reliability PCBA’s • Expert capability in manual reworking of complex surface-mount technology (SMT) & Pin Through Hole (PTH) including micro-size & complex components (e.g., 0201, 01005 passives, QFNs, as well as high-I/O count BGA’s & micro BGA’s) • Knowledge of, and experience with, semi-automated, robotic, & laser soldering processes & equipment • Expertise in non-destructive, complex repairs including trace/pad repair, laminate damage repair, & jumper wire additions • Intermediate Computer Skills • Strong Decision Making & Problem Solving Skills • Strong Verbal & Written Communications Skills • Strong Analytical & statistical analysis Skills; including SPC Software Skills • Ability to develop good working relationships with team members and customers Travel Requirements: • 25% or less. This document does not represent a contract of employment and is not intended to capture every possible assignment the incumbent could be asked to perform. We are pleased to provide reasonable accommodations to individuals with disabilities or special requirements. If you need an application accommodation, please contact us by email at GHQ.TA@plexus.com . Please include your contact information and clearly describe how we can help you. This email is for accommodation requests only and cannot be used to inquire about the status of applications. We are an Equal Opportunity Employer (EOE) and do not discriminate based on race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status. Some offers of employment are contingent upon successfully passing a drug screen and/or background check.

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