Optical Manufacturing Engineer

Job Description:

The Optical Manufacturing Process Consultant will provide subject matter expertise in spherical optical manufacturing processes, with a primary focus on process optimization, equipment transition, engineering capability development, and process standardization. This role will support the organization by auditing current manufacturing methods, optimizing OptoTech and OptiPro processing technologies, developing engineering knowledge, and ensuring robust process documentation to support sustainable operational excellence.

The successful candidate will possess extensive hands-on experience in optical generation, grinding, polishing, and process development, and be capable of transferring technical knowledge to engineers and technical staff.

 

Role and responsibilities

1. Process Audit and Continuous Improvement

Process Assessment

• Observe and assess current spherical optical manufacturing processes.
• Evaluate operator and engineering methods for compliance with established process standards.
• Identify process deviations, variation sources, inefficiencies, and technical risks.
• Conduct structured process audits and provide detailed findings and recommendations.

Process Optimization

• Recommend process improvements that enhance:
• • Quality
  • Throughput
  • Yield
  • Process capability
  • Cost performance
• Support implementation of corrective and preventive actions.
• Apply data-driven methodologies to improve process robustness and repeatability.

2. Orion Mk2 Development and NPI Support

OptoTech Process Development

• Optimize generation and high-speed polishing processes for optical components included within the Orion Mk2 and OptoTech NPI roadmap.
• Develop and validate manufacturing processes for new lens designs and optical products.
• Improve tooling strategies and process parameters to achieve required optical performance.

OptiPro Equipment Introduction

• Support transition activities from existing platforms to new OptiPro manufacturing systems.
• Assist in process development, machine qualification, and production readiness activities.
• Provide recommendations regarding equipment capabilities, process integration, and technology deployment.

Tooling Development

• Evaluate and optimize:
• • Generation tooling
  • Polishing tooling
  • Workholding solutions
  • Process consumables
• Develop best-practice guidelines for tooling selection and implementation.

3. Engineering Knowledge Transfer and Capability Development

Technical Training

• Train engineering personnel to develop a consistent understanding of:
• • Optical manufacturing fundamentals
  • OptoTech equipment operation
  • Process development methodologies
  • Best practices for process optimization

Process Understanding

• Educate engineers on critical process variables including:
• • Tool geometry
  • Feed rates
  • Speeds
  • Pressure
  • Slurry characteristics
  • Polishing parameters
  • Thermal influences
• Explain the relationship between process inputs and outputs such as:
• • Surface form
  • Surface roughness
  • Removal rate
  • Process capability
  • Yield performance

Troubleshooting Development

• Provide structured training on root cause investigation and process troubleshooting techniques.
• Coach engineers on identifying and resolving:
• • Surface defects
  • Process instability
  • Tool wear issues
  • Form errors
  • Machine-related variation

Tool Selection Guidance

• Establish guidelines and decision criteria for selecting:
• • Generation tools
  • Polishing tools
  • Conditioning methods
  • Process parameters

4. Documentation and Communication

Process Documentation

• Document all newly developed and modified manufacturing processes.
• Maintain transparency of all process changes through controlled documentation.
• Create or update:
• • Standard Operating Procedures
  • Process specifications
  • Training materials
  • Troubleshooting guides
  • Best-practice documents

Reporting

• Provide weekly progress reports to the management team.
• Present project status, risks, key findings, and recommendations.
• Communicate process changes, development activities, and improvement opportunities to stakeholders.

 Required Qualifications

• Bachelor's degree in Optical Engineering, Mechanical Engineering, Manufacturing Engineering, Physics, or related technical discipline.
• 10 years of experience in precision optical manufacturing.
• Extensive hands-on experience with:
• • Spherical optical generation
  • Grinding
  • High-speed polishing
• Process development and optimization
• Demonstrated experience with OptoTech manufacturing equipment.
• Strong understanding of optical metrology and process control techniques.
• Experience troubleshooting complex manufacturing processes.

 Preferred Qualifications

• Experience with OptoTech and/or OptiPro manufacturing equipment.
• Experience supporting New Product Introduction (NPI) programs.
• Knowledge of SPC, Six Sigma, Lean Manufacturing, and Design of Experiments (DOE).
• Experience developing and delivering technical training programs.

Additional Information

The physical demands described below represent those required to successfully perform the essential functions of this Process Engineer role. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Regular computer work requiring sitting, typing, and precise hand-eye coordination
• Frequent movement within the optics fabrication floor and office environments
• Occasional need to lift or move equipment, tooling, or materials weighing up to 20 pounds
• Required visual abilities include close vision, color differentiation (for inspection and analysis), and the ability to interpret detailed technical information
• Work performed primarily in an optics fabrication environment that may include exposure to noise, vibration, and various processing equipment
• Must be able to wear required PPE (personal protective equipment) including safety glasses, hearing protection, and other protective equipment as required in manufacturing areas
• Ability to analyze complex data, interpret technical documents, and communicate findings effectively
• Capability to respond to production issues in a timely manner, which may occasionally require extended periods of standing or walking through production areas with various fabrication equipment
• Some travel may be required to support global manufacturing and supplier interactions
• Candidates must be legally authorized to work in USA

GCR Professional Services is an engineering and information technology staffing firm (direct-hire, consultants, contract-to-hire).