Card Prototyping Coordinator

📍 Job Overview

Job Title: Card Prototyping Coordinator

Company: Thales

Location: Montgomeryville, Pennsylvania, United States

Job Type: FULL_TIME

Category: Operations - Manufacturing & Production Support

Date Posted: 2026-04-30

Experience Level: Entry Level (0-2 years)

Remote Status: On-site

🚀 Role Summary

• This role is critical for supporting the second shift operations of the card prototyping team, ensuring the continuous production of customer samples.

• The position involves direct oversight and participation in various stages of card sample manufacturing, from initial printing to final assembly and shipment.

• A key aspect of this role is acting as a backup for specialists, demonstrating a broad understanding of prototyping processes and a willingness to support team needs.

• The coordinator will be responsible for managing material procurement and ensuring the efficient and organized operation of the prototyping lab and shop floor.

📝 Enhancement Note: While the title "Card Prototyping Coordinator" and core responsibilities suggest a hands-on production role, the term "Coordinator" implies a need for organizational skills, communication, and some level of process oversight. This role is positioned to bridge the gap between skilled specialists and the broader manufacturing process, requiring a proactive approach to problem-solving and team support within a production environment. It's not a traditional "operations" role in the sense of revenue or sales ops, but rather within the manufacturing operations of a tech/security company.

📈 Primary Responsibilities

• Production Support: Actively participate in and support all card sample manufacturing processes, from sheet printing through final product assembly and preparation for shipping.

• Shift Coordination: Coordinate directly with the printing and New Product Introduction (NPI) teams to manage work handovers from the previous shift and ensure seamless workflow continuity.

• Artwork & Color Management: Support color correction processes for artwork designs, ensuring visual accuracy and adherence to customer specifications.

• Press Operation Guidance: Provide clear direction to digital and silkscreen press operators regarding the day's work requirements and production targets.

• Manual Process Execution: Support and execute manual processes including perforation, sheet collation, lab lamination, and manual punching, ensuring quality and efficiency.

• Process Learning & Autonomy: Proactively learn additional manual printing processes to gain the ability to operate them autonomously, specifically to bolster second-shift capabilities.

• Material Management: Utilize Product Data Management (PDM) systems and collaborate with logistics personnel to accurately order necessary materials for prototyping.

• Sample Shipment: Assist in the preparation and shipment of customer card samples, ensuring timely delivery and proper documentation.

• New Product Qualification: Contribute to the qualification processes for new products, providing feedback and support during testing and validation phases.

• Lab & Shop Floor Maintenance: Ensure the proper housekeeping and organization of the prototyping lab and shop floor areas, adhering to safety and operational standards.

📝 Enhancement Note: The responsibilities highlight a blend of direct production tasks and coordination duties. The emphasis on learning new processes and supporting the second shift indicates a need for flexibility and a strong work ethic. The role requires someone who can not only perform tasks but also understand the flow and dependencies within the prototyping workflow.

🎓 Skills & Qualifications

Education:

Experience:

• Demonstrated technical ability with both manual and machine operations.

• Experience in a card manufacturing setting is a significant plus but not strictly required.

Required Skills:

• Basic Math & Reading Comprehension: Ability to perform basic calculations and understand technical instructions.

• Technical Aptitude: Proven hands-on capability with manual tasks and operating machinery.

• Customer Focus: A strong understanding of customer needs and a commitment to delivering high-quality samples.

• Autonomy & Initiative: Ability to work independently with minimal direct supervision and take initiative to solve problems.

• Teamwork: A cooperative and collaborative approach to working with colleagues and supporting team objectives.

• Communication Skills: Effective verbal communication to provide direction and coordinate with team members.

Preferred Skills:

• Microsoft Office Suite: Basic proficiency in Microsoft Excel and Word for documentation and data entry.

• Dynamic Personality: An energetic and adaptable individual who thrives in a fast-paced production environment.

• Prototyping/Manufacturing Experience: Prior experience specifically within card manufacturing or a similar prototyping/production setting.

📝 Enhancement Note: The qualifications emphasize foundational skills and a willingness to learn, aligning with an entry-level to early-career operations support role. The preference for Microsoft Excel and Word skills suggests a need for basic data handling and reporting capabilities, even within a production context.

📊 Process & Systems Portfolio Requirements

Portfolio Essentials:

• Process Documentation: While a formal portfolio isn't explicitly mentioned, candidates should be prepared to discuss their experience with process execution and any documentation they've been involved with. This could include:

  • Documenting steps for manual processes they've performed.
  • Explaining workflow sequences they've followed or improved.
  • Examples of how they've ensured quality control in their tasks.

• System Interaction: Be ready to describe how you've interacted with production or material management systems (like PDM or logistics tracking) and your ability to learn new software quickly.

• Problem-Solving Examples: Prepare to share specific instances where you identified an issue in a process and took steps to resolve it, demonstrating initiative and a solutions-oriented mindset.

• Efficiency Contributions: Think about any times you've contributed to making a process faster, more accurate, or more organized, even in small ways.

Process Documentation:

• The role requires contributing to the maintenance of a well-organized prototyping lab and shop floor. This implies an understanding of:
  • Workflow Design: Familiarity with sequential processes, from raw materials to finished goods.
  • Execution Standards: Adherence to established procedures for tasks like printing, lamination, and punching.
  • Performance Feedback: Ability to provide input on process steps that could be improved or optimized for efficiency and quality.

📝 Enhancement Note: Given the entry-level nature and focus on production support, the "portfolio" for this role will likely be demonstrated through interview discussions and behavioral examples rather than formal work samples. Candidates should prepare to articulate their practical experience and problem-solving skills in a manufacturing context.

💵 Compensation & Benefits

Salary Range:

• Estimated Range: $48,601.62 - $86,332.49 USD Annually

• Explanation: This range is based on the provided Total Target Cash (TTC) figures from Thales. This range is competitive for an entry-level to mid-level production support role in the Montgomeryville, PA area, considering the specialized nature of card prototyping and the security industry context. Factors like specific experience in card manufacturing, technical skills, and performance during the interview process will influence the final offer within this band.

Benefits:

• Health & Wellness: Elective Health, Dental, Vision, Flexible Spending Accounts (FSA/HSA), Critical Illness, Hospital Indemnity, Accident Insurance, Employee Assistance Program (EAP), and Well-being Program.

• Insurance: Voluntary Life and Accidental Death & Dismemberment (AD&D) insurance, Whole Group Life with Long-Term Care (LTC) coverage.

• Retirement: Retirement Savings Plan available after 30 days of employment with company contribution and match, and no vesting period.

• Time Off: Company-paid holidays and Paid Time Off (PTO).

• Additional Perks: Legal Plan, Identity Theft Protection, and Pet Insurance.

• Company Provided: Life Insurance, AD&D, Disability Insurance.

Working Hours:

• This is a full-time position. The role specifically supports the second shift, implying working hours outside of standard business hours, likely with a standard 8-hour shift plus potential for overtime. The total expected hours per week are 40.

📝 Enhancement Note: The provided salary range is quite broad for an entry-level role. The lower end aligns with typical entry-level manufacturing support, while the higher end suggests room for growth or compensation for highly relevant prior experience. The extensive benefits package is a significant draw, particularly the immediate vesting and match on the retirement plan.

🎯 Team & Company Context

🏢 Company Culture

Industry: Technology & Aerospace/Defense (Security focus). Thales specializes in identity management, data protection, and digital security solutions for governments and businesses, spanning critical sectors like banking, transportation, and energy.

Company Size: Thales is a large, multinational corporation with over 30,000 employees globally, indicating a structured corporate environment with established processes and potential for career advancement.

Founded: Thales has a long history, tracing its roots back many decades, suggesting stability, extensive experience, and a deep understanding of its core markets.

Team Structure:

• Prototyping Team: This role is part of a specialized card prototyping team, likely comprising skilled technicians, specialists, and potentially engineers.

• Reporting: The coordinator will report to a supervisor or manager overseeing the prototyping department, likely within a larger manufacturing or product development division.

• Collaboration: Close collaboration is expected with printing teams, NPI specialists, logistics, and potentially R&D or product management for new product qualification.

Methodology:

• Data-Driven Production: While hands-on, the role operates within a company that values data for security and product development. Expect adherence to precise specifications and potential use of data from systems like PDM.

• Process Optimization: There's an implied focus on efficiency and quality in production, with opportunities to learn and contribute to process improvements.

• Quality Assurance: Given the security focus, adherence to strict quality standards and procedures is paramount.

Company Website: https://www.thalesgroup.com/

📝 Enhancement Note: Working for a large, established company like Thales means operating within a robust framework of policies, procedures, and quality standards. The security aspect of their business suggests a high level of diligence and attention to detail will be expected across all roles, including this production support position.

📈 Career & Growth Analysis

Operations Career Level: This position is positioned at an entry-level to early-career stage within manufacturing operations. It's ideal for individuals looking to gain foundational experience in production processes, particularly in a specialized technical field like card manufacturing.

Reporting Structure: The Card Prototyping Coordinator will likely report to a Lead Technician, Prototyping Supervisor, or a Production Manager. This role serves as a crucial support function within the prototyping team, facilitating the work of more senior specialists.

Operations Impact: While not directly client-facing or revenue-generating in a sales capacity, this role has a significant impact on Thales' ability to deliver critical security products. By ensuring timely and accurate production of customer samples, the coordinator directly supports sales efforts, product development cycles, and customer satisfaction, which are foundational to sustained business growth and market trust.

Growth Opportunities:

• Skill Specialization: Opportunity to become a highly skilled technician in card manufacturing processes, including printing, lamination, and punching, potentially leading to specialist roles.

• Process Improvement: Develop expertise in identifying inefficiencies and contributing to process optimization within the prototyping lab, potentially moving into roles focused on manufacturing engineering or process improvement.

• Team Leadership: With demonstrated performance and leadership potential, there may be opportunities to advance into team lead or supervisory roles within the production or prototyping departments.

• Cross-Functional Exposure: Gaining exposure to NPI, logistics, and potentially R&D provides a broader understanding of product lifecycle management within a technology company.

📝 Enhancement Note: Growth in this role will likely be vertical within manufacturing operations rather than lateral into sales or revenue operations. The emphasis on learning and skill development suggests a clear path for individuals who excel in hands-on technical work and process adherence.

🌐 Work Environment

Office Type: This is an on-site position requiring presence at the Montgomeryville, PA facility. The work environment will involve a combination of office-based tasks (e.g., PDM usage, coordination) and significant time spent in a laboratory and shop floor setting.

Office Location(s): The primary work location is Montgomeryville, Pennsylvania. This is a manufacturing and corporate site, likely equipped with specialized machinery and resources for prototyping.

Workspace Context:

• Laboratory/Shop Floor: A hands-on environment with specialized equipment for printing, lamination, punching, and assembly of cards. This area will require adherence to safety protocols and organized workflow.

• Tools & Technology: Access to PDM systems, basic office software (Excel, Word), and the machinery involved in card production.

• Team Interaction: Frequent interaction with fellow team members, press operators, specialists, and potentially supervisors or engineers, fostering a collaborative, production-focused atmosphere.

Work Schedule: The role is for the second shift, meaning typical working hours will be outside of the standard 9-to-5 day. This schedule is crucial for providing continuous production support and ensuring timely sample delivery. The standard work week is 40 hours.

📝 Enhancement Note: Candidates should be comfortable with a physically active role in a production environment and understand the demands of a second-shift schedule. The integration of lab work with some administrative tasks means adaptability to different work settings within the facility is key.

📄 Application & Portfolio Review Process

Interview Process:

• Initial Screening: Likely a review of your application and resume to assess basic qualifications, technical aptitude, and relevant experience.

• Hiring Manager Interview: A discussion focused on your experience with manual/machine work, your understanding of production processes, problem-solving abilities, and suitability for the second shift. Be prepared to discuss your experience with the listed "Key Areas of Responsibility."

• Technical/Practical Assessment: This might involve a hands-on demonstration of a relevant skill or a discussion about how you would approach a specific task (e.g., color correction, material ordering).

• Team/Cultural Fit Interview: An opportunity to meet potential colleagues and assess your fit within the team's collaborative and autonomous work style.

• Final Interview: Potentially with a more senior manager to confirm fit and discuss compensation.

Portfolio Review Tips:

• Articulate Experience: Since a formal portfolio isn't standard for this type of role, focus on verbally presenting your experience. Clearly describe your responsibilities in previous roles, highlighting any involvement in manufacturing, prototyping, machine operation, or process coordination.

• Process Examples: Be ready to walk through a process you've been involved in, from start to finish. Explain your role, the steps involved, any challenges encountered, and how you contributed to a successful outcome.

• Problem-Solving Scenarios: Prepare 2-3 examples of challenges you've faced in a work setting and how you approached solving them. Focus on your initiative, critical thinking, and the results of your actions.

• System Familiarity: Discuss any experience you have with production systems, inventory management (like PDM), or basic data entry tools (Excel). Emphasize your ability to learn new systems quickly.

Challenge Preparation:

• Scenario-Based Questions: Expect questions like: "How would you handle a situation where the printing quality isn't meeting specifications?" or "What steps would you take if you ran out of a critical material for a sample order?"

• Time Management: Be ready to discuss how you prioritize tasks, especially when working under time constraints on a second shift.

• Communication Clarity: Practice explaining technical concepts or process steps clearly and concisely, as if you were explaining them to a new team member.

📝 Enhancement Note: The application process will likely focus heavily on behavioral and situational questions. Candidates should prepare to demonstrate their practical skills, problem-solving abilities, and commitment to quality and teamwork through concrete examples.

🛠 Tools & Technology Stack

Primary Tools:

• PDM (Product Data Management): Essential for material ordering and potentially tracking prototype versions. Familiarity with PDM systems or similar inventory/product tracking software is valuable.

• Digital & Silkscreen Printing Presses: Direct experience or understanding of operating these types of industrial printing equipment.

• Lamination & Punching Equipment: Experience with machinery used for card finishing processes.

• Manual Tools: Proficiency with hand tools and equipment used in manual assembly and perforation.

Analytics & Reporting:

• Microsoft Excel: Basic to intermediate skills for data tracking, reporting, and potentially simple analysis related to material usage or production output.

• Microsoft Word: For documentation, reporting, and communication.

CRM & Automation:

• Logistics Systems: Interaction with systems or processes for managing material procurement and sample shipment.

• Basic Data Entry: Comfort with inputting data into operational systems accurately.

📝 Enhancement Note: While specific software names beyond PDM aren't listed, the core requirements point to a need for hands-on experience with manufacturing equipment and basic office productivity tools. The emphasis is on operational execution and system interaction rather than complex data analysis or CRM management.

👥 Team Culture & Values

Operations Values:

• Quality & Precision: A strong emphasis on accuracy and meeting specifications, critical for security products and customer samples.

• Efficiency & Productivity: A drive to optimize workflows and maintain high output levels, especially during the second shift.

• Reliability & Dependability: Being a consistent and trustworthy member of the team, especially crucial for shift work and process continuity.

• Collaboration & Teamwork: A culture that values mutual support, clear communication, and working together to achieve shared production goals.

• Safety & Housekeeping: Adherence to safety protocols and maintaining a clean, organized workspace is fundamental in a manufacturing setting.

Collaboration Style:

• Cross-Functional Integration: Working closely with printing, NPI, and logistics teams to ensure smooth transitions and material availability.

• Direct Communication: Open and clear verbal communication is key for providing direction, reporting issues, and coordinating tasks with colleagues and press operators.

• Mutual Support: A willingness to assist team members, back up specialists, and share knowledge to ensure team success, particularly during busy periods or shift changes.

📝 Enhancement Note: Thales's focus on security and technology suggests a culture that values diligence, technical competence, and a professional approach. The emphasis on teamwork and reliability is particularly important for a role supporting a specific shift and production cycle.

⚡ Challenges & Growth Opportunities

Challenges:

• Second Shift Operations: Adapting to and maintaining productivity during non-standard working hours.

• Process Complexity: Learning and mastering a variety of manual and machine-based card production processes.

• Balancing Tasks: Effectively managing direct production duties, coordination responsibilities, and material procurement in a dynamic environment.

• Quality Control: Consistently meeting strict quality standards for prototyping and sample production.

• NPI Contribution: Supporting the integration of new products which may involve evolving processes and requirements.

Learning & Development Opportunities:

• Advanced Prototyping Skills: Deepen expertise in specialized card manufacturing techniques, potentially leading to certification or advanced technician roles.

• Process Improvement Contribution: Gain experience in identifying bottlenecks and suggesting improvements to production workflows, contributing to operational efficiency.

• Cross-Functional Understanding: Develop a broader perspective on product development and manufacturing by interacting with different departments.

• Exposure to Security Technology: Understand the foundational aspects of identity management and data protection technologies through the products being prototyped.

📝 Enhancement Note: The challenges in this role are typical of production support positions, emphasizing adaptability and a commitment to learning. The growth opportunities are centered on developing technical expertise within manufacturing and contributing to process efficiency.

💡 Interview Preparation

Strategy Questions:

• Process Understanding: "Describe your experience with manufacturing or production processes. What steps are involved in creating a product from raw materials to a finished item?"

• Problem-Solving: "Tell me about a time you encountered an issue during a manual or machine operation. What did you do to resolve it?"

• Teamwork & Communication: "How do you ensure clear communication with your team, especially when working a second shift or with colleagues on different shifts?"

• Adaptability: "This role requires learning new processes. How do you approach learning new technical skills or operating new equipment?"

• Quality Focus: "Why is attention to detail important in a prototyping or manufacturing role, especially in a company focused on security?"

Company & Culture Questions:

• Company Knowledge: "What do you know about Thales and its role in digital security?"

• Work Environment Fit: "This role is on-site and involves a second shift. How do you feel about this work arrangement?"

• Team Dynamics: "How do you contribute to a positive team environment, and what are your expectations from your colleagues?"

Portfolio Presentation Strategy:

• Verbal Walkthroughs: Be prepared to verbally describe specific processes you've worked on. Use the STAR method (Situation, Task, Action, Result) to structure your answers about past experiences.

• Highlight Technical Aptitude: Emphasize any experience you have operating machinery, performing manual tasks, or working with technical equipment.

• Demonstrate Learning Ability: Clearly articulate your eagerness and capacity to learn new skills and adapt to new technologies.

• Focus on Results: Even for small tasks, try to quantify or describe the positive outcomes of your work (e.g., "ensured all samples were ready for shipment on time," "helped maintain an organized workspace").

📝 Enhancement Note: Interviewers will be looking for a blend of technical aptitude, a proactive attitude, strong communication skills, and a commitment to quality and teamwork. Preparing specific examples from past work or even personal projects that demonstrate these qualities will be highly beneficial.

📌 Application Steps

To apply for this operations position:

• Submit your application through the Thales careers portal link provided.

• Resume Optimization: Tailor your resume to highlight any experience with manufacturing, production, machine operation, technical tasks, quality control, or coordination roles. Use keywords from the job description such as "prototyping," "printing," "manual processes," "coordination," and "technical ability."

• Prepare Your Narrative: Think about specific examples that showcase your basic math skills, demonstrated technical ability, customer focus, autonomy, teamwork, and communication skills. Practice articulating these using the STAR method.

• Research Thales: Familiarize yourself with Thales's products, especially their identity management and digital security solutions, and understand their market position. This will help you speak knowledgeably during the interview.

• Articulate Second Shift Readiness: Be prepared to discuss your comfort and suitability for working the second shift and your understanding of its demands on productivity and coordination.

⚠️ Important Notice: This enhanced job description includes AI-generated insights and operations industry-standard assumptions. All details should be verified directly with the hiring organization before making application decisions.