Manufacturing NPI Test Engineer

Position Summary

The Manufacturing NPI Test Engineer is the bridge between Test Engineering and Production for the production testing of new power supplies and converters from introduction at our US factory through transfer to volume production at our Vietnam factory. Working closely with Test Engineering on test development tester updates and troubleshooting you will own the deployment of production test for new products and of improvements to existing test ensuring every unit is tested accurately efficiently and in compliance with quality requirements.

In this role you will support multiple concurrent NPI programs own the transfer of production test to our Vietnam factory and serve as the go-to production test resource for existing products driving test yield uptime and test-time improvements. This is a hands-on on-site role. You will spend significant time on the production floor and work closely with Test Engineering Manufacturing NPI Engineering Design Engineering Quality and Production.

Key Responsibilities

New Product Introduction Production Test

• Represent production test on cross-functional NPI teams; provide design-for-test (DFT) input in design reviews including test point access fixturing and test coverage.
• Partner with Test Engineering to define the production test strategy for each new product across ICT/flying probe functional/ATE hipot/safety and burn-in/ESS.
• Work with Test Engineering on the development of new test stations fixtures and test software; review test specifications and procedures for production readiness test time and operator usability.
• Own the deployment of production test for new products: installation debug and release of test stations fixtures test programs and limits to the production floor.
• Validate production test through test method validation repeatability and Gage R&R studies golden-unit correlation and correlation to design verification data.
• Support EVT/DVT/PVT pilot and first production builds with test resources; analyze test data identify failure trends and drive root cause with Design and Test Engineering.
• Define test readiness criteria and sign off on release of test to production including first-pass yield test time documentation and operator training.
• Develop and maintain test work instructions test procedures and operator troubleshooting guides.

Production Test Transfer to Vietnam

• Own the transfer of production test for released products from the US site to the Vietnam factory working with the Manufacturing NPI Engineer and the Vietnam receiving team to develop and execute the test transfer plan schedule risk mitigation and readiness milestones.
• Prepare and hand over a complete test transfer package: test specifications and procedures revision-controlled test software and limits station configurations fixture drawings and BOMs calibration and maintenance requirements and known failure modes and troubleshooting guides.
• Coordinate replication or shipment of test stations fixtures and burn-in equipment and verify equivalent setup configuration and calibration at the receiving site.
• Lead US-to-Vietnam test correlation (golden units cross-site correlation studies) and confirm the receiving site meets test yield test time and quality targets.
• Train the Vietnam test engineers and technicians on test operation debug maintenance and failure analysis both on-site in Vietnam and remotely; confirm competency through training records and supervised builds.
• Formally hand over test ownership to the receiving team once capability is demonstrated and provide follow-up support to resolve post-transfer test issues.

Sustaining Production Test

• Serve as the primary production-floor test resource for existing products; troubleshoot tester fixture and test software issues to minimize line downtime.
• Monitor test yield false failures retest rates and test time; work with Test Engineering to improve testing through limit optimization fixture improvements software updates and test-time reduction.
• Own the deployment of tester updates and improvements to production under change control including verification release and documentation of software and limit revisions.
• Maintain test equipment and fixtures including preventive maintenance fixture wear and pogo pin replacement spares and calibration scheduling and records.
• Support failure analysis of test failures early-life failures and customer returns; feed results back to Design Test Engineering and Manufacturing.
• Identify justify (business case/ROI) specify procure and qualify test equipment and automation improvements.

Test Equipment & Methods

• Functional / ATE Deploy and support functional test using programmable AC/DC sources electronic loads power analyzers oscilloscopes and DMMs covering efficiency regulation ripple and noise transient response start-up timing and protection features (OVP/OCP/OTP).
• Safety Test Deploy and maintain hipot insulation resistance ground bond and leakage current testing per IEC 60601-1 and IEC 62368-1 including daily safety tester verification.
• Burn-In / ESS Support burn-in racks load banks and thermal cycling; work with Quality to define and optimize burn-in and ESS profiles.
• ICT / Flying Probe Support PCBA-level test program and fixture deployment coverage review debug and false-call reduction.

Quality & Compliance

• Provide test inputs to PFMEAs and control plans and maintain test method validation documentation in line with ISO 9001 and ISO 13485 requirements; support IQ/OQ/PQ where required.
• Ensure test equipment calibration test software version control and serial-level traceability of test records meet medical quality requirements.
• Lead root cause analysis (8D 5-Why Ishikawa) for test escapes and test-related nonconformances; implement and verify corrective actions.
• Represent production test in internal customer and notified-body/regulatory audits.

Documentation & Systems

• Manage test software limits and procedures under revision control; process test-related ECOs/ECNs through PLM and manage product revision cut-ins at test.
• Use test data and SPC to monitor test performance; maintain yield failure Pareto and test-time reporting for production and engineering.

Mentoring Training & Communication

• Mentor test technicians and junior engineers and serve as the go-to production test resource for production and engineering teams.
• Train production operators and test technicians on new test stations and procedures including safe operation of high-voltage test equipment.
• Communicate test status risks and mitigation plans clearly to cross-functional teams management and customers when required.

Qualifications :

Required Qualifications

• 68 years of test production test or test engineering experience in electronics manufacturing ideally power electronics.
• Proven experience deploying and sustaining production test for new products from pilot through volume production across multiple concurrent programs.
• Hands-on production experience with functional/ATE hipot/safety burn-in/ESS and ICT or flying probe test.
• Proficiency in at least one test development platform NI LabVIEW NI TestStand or Python with the ability to read debug and modify test software.
• Strong bench instrument skills (programmable sources electronic loads oscilloscopes power analyzers DMMs) and instrument control (GPIB USB LAN SCPI).
• Experience transferring test between manufacturing sites preferably to an overseas factory including correlation and training receiving teams.
• Ability to read schematics PCB layouts assembly drawings and test specifications; strong electronic troubleshooting skills to component level.
• Working knowledge of ISO 9001; experience in an ISO 13485 or other regulated (medical) environment including test method validation and test software change control.
• Strong command of structured problem solving (8D 5-Why) SPC and MSA/Gage R&R.
• Comfortable working safely around high-voltage test equipment and on an active production floor.
• Strong communication skills and the ability to influence and coordinate cross-functional teams.

Preferred Qualifications

• Bachelors degree in Electrical or Electronics Engineering (or Computer Engineering) or equivalent hands-on experience (e.g. progression from senior test technician with demonstrated engineering-level responsibility).
• Experience testing AC-DC power supplies and/or DC-DC converters (e.g. switch-mode topologies protection circuits efficiency and thermal performance).
• Familiarity with IEC 60601-1 and IEC 62368-1 production safety tests (hipot leakage current ground bond).
• Proficiency in more than one of LabVIEW TestStand and Python; NI certification (e.g. CLD CTD) a plus.
• Working experience with SolidWorks for test fixture design and reviewing 3D models and drawings.
• Experience with ICT/flying probe platforms (e.g. Keysight Teradyne Takaya SPEA).
• Hands-on IQ/OQ/PQ and test method validation experience in a regulated (medical) environment.
• Lean Six Sigma Green Belt (or higher); proficiency with Minitab.
• Experience with test data management MES or databases (e.g. SQL) for test traceability and reporting.
• Experience working with manufacturing teams in Southeast Asia; Vietnamese language skills a plus.

Background & Knowledge Areas

Ideal candidates will bring practical understanding in the following areas:

• Power electronics fundamentals switch-mode power conversion isolation protection circuits efficiency and thermal behavior and how these show up as test parameters and failure modes.
• Test strategy & coverage balancing ICT functional safety and burn-in for coverage cost and test time; design-for-test principles.
• Measurement science instrument accuracy and uncertainty grounding and Kelvin connections ripple and noise measurement techniques MSA and guard-banding of test limits.
• Test fixture design bed-of-nails and pogo pin fixtures high-current and high-voltage interconnects and safety interlocks.
• Regulated quality systems test method and software validation change control traceability and documentation practices under ISO 13485.
• Production test operations throughput station utilization and calibration and maintenance programs for low-to-medium volume high-mix production.

Tools & Systems

• Test software NI LabVIEW NI TestStand Python (proficiency in at least one)
• Test equipment programmable AC/DC sources electronic loads power analyzers oscilloscopes hipot/safety testers burn-in systems ICT/flying probe
• ERP/MRP and PLM e.g. Oracle / SAP; Agile / Arena
• Mechanical CAD SolidWorks (preferred)
• Quality & analysis SPC MSA/Gage R&R Minitab PFMEA control plans
• Office Microsoft 365 (Excel PowerPoint Project or equivalent)

Work Environment & Physical Requirements

• Based on-site at our US manufacturing facility (no remote work); regular time on the production floor.
• Work around high-voltage test stations burn-in equipment electronic assembly equipment and chemicals (solder flux); adherence to ESD high-voltage and safety procedures required. PPE provided.
• Ability to stand/walk for extended periods and lift up to 25 lbs.
• Travel 1020% domestic and international travel primarily to our Vietnam factory to lead test transfers equipment setup and correlation and on-site training (trips may last 13 weeks) as well as to suppliers customers and other XP Power sites. A valid passport is required or must be obtained.
• Occasional flexibility to support builds and production test issues outside standard hours.

Additional Information :

XP Power provides a safe and healthy working environment that is stimulating and collaborative where employees are empowered to make a real difference. We place our people at the heart of everything we do. We understand that if we provide our people with the ultimate experience they will provide the ultimate experience to our customers. 

We also offer a comprehensive benefits package including:

• 100% Employer Paid Medical Dental and Vision Insurance for full-time Employee-only coverage; you share the cost of coverage for your dependents
• Company Paid Bonus (Percentage dependent on Company profitability)
• Company 401(k) Match (up to 6%)
• Mental Health Benefits
• Paid Time Off (Accrued per pay period starting at 3 weeks per year)
• 13 Company Paid Holidays 
• Paid Time Off for Volunteer Work (up to 8 hours per year)
• Employer Paid Supplemental Short-Term and Long-Term Disability Insurance 
• Veterinary Pet Insurance
• Company Social Events held throughout the year
• A Friendly Culture Where People Collaborate and Strive for Excellence

All your information will be kept confidential according to EEO guidelines.

Remote Work :

No

Employment Type :

Full-time