Debug Test Technician

XP Power•San Jose, CA

4d•Onsite

About The Position

The Debug Test Technician troubleshoots and repairs power supply assemblies from top-level assembly (TLA) down to printed circuit board assembly (PCBA) and component level. The role supports volume production, new product introduction (NPI) and pilot builds, and customer returns (RMA), helping failed units return to production and contributing to yield and quality improvements. The technician diagnoses power-conversion circuit failures, performs rework to IPC workmanship standards, records failure data, and helps maintain functional test stations. This is a hands-on, on-site position split between the production floor and debug lab, collaborating with Test, Manufacturing, and Design Engineering, Quality, and Production. The role includes debugging and repairing power supplies using schematics, bills of materials, and assembly drawings; diagnosing failures in power-factor-correction stages, primary-side switching, magnetics, isolated feedback loops, secondary-side regulation, and protection circuits; and verifying repaired units through retest. It also supports NPI builds and customer-return analysis, performs SMT and through-hole rework, documents failures and repairs with serial-level traceability, contributes data to failure analysis and corrective-action work, and maintains and troubleshoots functional test fixtures and stations. The position is based on-site at a US manufacturing facility, with day-shift hours. Work is performed around energized high-voltage assemblies, test stations, and soldering materials such as solder and flux. PPE is provided, and ESD, high-voltage, and safety procedures must be followed. The role requires sitting or standing at a bench for extended periods, fine-pitch work under magnification, and lifting up to 25 pounds. Occasional flexibility may be needed to support builds and production issues outside standard hours.

Requirements

2–5 years of hands-on TLA and PCBA debug experience in electronics manufacturing; experience with switch-mode power supplies is described as ideal.
Solid understanding of analog and power electronics, including rectification, PFC, flyback/forward/resonant topologies, feedback loops, and protection circuits.
Ability to read and work from schematics, BOMs, and assembly drawings and troubleshoot to component level.
Proficiency with oscilloscopes, including differential and current probes, and digital multimeters.
Experience with programmable AC sources, electronic loads, and power analyzers.
Skill in SMT and through-hole soldering and rework, including fine-pitch parts.
Safe working habits around high voltage and ESD-sensitive assemblies.
Clear written documentation of failures and repairs; comfort using Excel and MES or failure-tracking systems.
Ability to prioritize work across production, NPI, and RMA activities.
Ability to sit or stand at a bench for extended periods, perform fine-pitch work under magnification, and lift up to 25 pounds.
Adherence to ESD, high-voltage, and safety procedures.
Occasional flexibility to support builds and production issues outside standard hours.

Nice To Haves

Associate's degree in Electronics Technology or similar, or equivalent military or vocational training and hands-on experience.
Current IPC-A-610 and/or J-STD-001 certification.
Experience supporting NPI builds or RMA/failure analysis in a contract or OEM manufacturing environment.
Familiarity with 8D, 5-Why, and corrective-action processes.
Experience maintaining functional test fixtures or automated test stations.
Experience in an ISO 9001 or ISO 13485 regulated environment.

Responsibilities

Debug and repair failed power supplies from top-level assembly down to PCBA and component level using schematics, BOMs, and assembly drawings.
Diagnose failures in PFC stages, primary-side switching, magnetics, isolated feedback loops, secondary-side regulation, and protection circuits.
Turn around boards that fail in-circuit or functional test to keep work in progress moving and support first-pass yield.
Retest repaired units and confirm they meet specifications before returning them to the production line.
Debug failures on NPI and pilot builds and help engineering distinguish design, process, and component issues.
Provide hands-on feedback about debug access, test points, and repairability during early builds.
Reproduce reported failures on customer returns, determine root causes, and repair or disposition units.
Document RMA findings for Quality and Engineering to support customer responses and corrective action.
Perform SMT and through-hole soldering and rework, including fine-pitch components, using hot-air and rework stations.
Follow IPC-A-610 workmanship standards and ESD-safe handling practices.
Log failures, root causes, and repair actions in the failure database or MES with serial-level traceability.
Build failure Pareto and trend reports, flag emerging issues, and provide data and analysis for 8D and CAPA investigations.
Collaborate with Test, Design, and Manufacturing Engineering on recurring defects and suggest DFM/DFT improvements.
Communicate debug status, findings, and risks to engineering and production leads.
Maintain and troubleshoot functional test fixtures and stations, including AC sources, electronic loads, wiring, and interfaces.
Support fixture upkeep, including pogo-pin replacement and connector-wear maintenance, and escalate tester issues to Test Engineering.

Benefits

100% employer-paid medical, dental, and vision insurance for full-time employee-only coverage; employees share the cost of dependent coverage.
Company-paid bonus, with percentage dependent on company profitability.
Company 401(k) match up to 6%.
Mental health benefits.
Paid time off accrued per pay period, starting at three 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 throughout the year.
A friendly culture where people collaborate and strive for excellence.
PPE provided.