Engineering Manager - AI Server RMA (Field Repair) Operation

Foxconn Industrial Internet - FII•Houston, TX

12d

About The Position

The Engineering Manager is responsible for the technical performance of the AI server RMA and field-repair operation, including server diagnostics, root-cause analysis, repair-process development, liquid-cooling integrity, test validation, repair yield, and customer technical escalations. The role combines technical expertise with hands-on factory leadership, managing engineers and partnering with Manufacturing, Quality, Test Engineering, Process Engineering, Supply Chain, Program Management, suppliers, and customer engineering teams. The goal is to restore customer systems rapidly while identifying and eliminating the root causes of recurring failures. The manager leads engineers supporting customer returns, RMA repair, refurbishment, and field-failure investigations; establishes standardized diagnostic, repair, validation, and escalation processes; and provides technical leadership for complex AI server failures. The role develops engineering staff and technicians, manages resources according to customer severity and business risk, and drives investigations from symptom reproduction through validated corrective action and closure. The Engineering Manager also analyzes RMA and field-failure data, leads structured problem-solving investigations, reduces unnecessary component replacement and No Trouble Found cases, and partners across engineering, manufacturing, quality, suppliers, and customers to implement permanent corrective actions. The role provides senior technical escalation support, communicates complex failures to technical and executive audiences, and feeds RMA lessons learned and serviceability feedback into NPI and future AI server platforms. Success balances repair speed, technical accuracy, product quality, cost, and customer satisfaction.

Requirements

Bachelor's degree in Electrical, Electronics, Computer, Mechanical, or Manufacturing Engineering, or a related technical discipline; equivalent relevant technical and leadership experience may be considered.
At least 5 years of engineering experience in servers, computing, electronics, networking, high-tech manufacturing, or related industries.
At least 3 years of engineering leadership or people-management experience.
Strong experience with system-level troubleshooting, failure analysis, manufacturing, repair, RMA, NPI, or field-return operations.
Demonstrated ability to lead complex root-cause investigations and corrective actions.
Experience working directly with customers, suppliers, or customer engineering organizations.
Hands-on technical leadership and willingness to engage directly in complex debugging situations.
Strong root-cause and structured problem-solving discipline.
Data-driven decision-making and KPI ownership.
Ability to lead engineering teams in a fast-paced factory/RMA environment.
Strong customer focus and urgency without sacrificing technical rigor.
Effective cross-functional and supplier leadership.
Clear written, verbal, and executive-level communication.
Ability to develop engineers, technical leads, and repair technicians.

Nice To Haves

Experience with AI, GPU, HPC, hyperscale, or enterprise server platforms.
Knowledge of GPU/CPU architecture, DDR memory, PCIe, NVMe, and high-speed networking.
Experience with BMC, BIOS, firmware, telemetry, and system-event-log diagnostics.
Experience with liquid cooling, cold plates, QDs/QDCs, manifolds, coolant handling, flow and pressure fundamentals, and leak testing.
Experience in high-volume electronics manufacturing and RMA operations.
Familiarity with 8D, FMEA, SPC, DOE, CAPA, and Six Sigma methodologies.
Experience with MES, PLM, QMS, ERP, and RMA tracking systems.
Experience in ISO 9001 or similar quality-management environments.
Experience with accelerated-computing or advanced GPU server architectures.

Responsibilities

Lead engineers supporting customer returns, RMA repair, refurbishment, and field-failure investigations.
Establish standardized diagnostic, repair, validation, and engineering escalation processes.
Provide technical leadership for complex AI server failures that cannot be resolved through standard troubleshooting procedures.
Manage engineering resources based on customer severity, RMA aging, production impact, and business risk.
Develop engineers and technicians through coaching, technical training, certification, and structured problem-solving practices.
Drive failures through a disciplined process from symptom and reproduction through isolation, root cause, corrective action, validation, and closure.
Reduce unnecessary component replacement, repeated troubleshooting, and No Trouble Found cases.
Lead structured investigations using methods such as 8D, 5 Why, Fishbone, Pareto, FMEA, fault-tree analysis, DMAIC, and DOE, as appropriate.
Analyze RMA and field-failure data to identify product, process, supplier, firmware, workmanship, and test-coverage improvement opportunities.
Partner with Design, Manufacturing, Quality, suppliers, and customer engineering teams to implement permanent corrective actions.
Provide RMA lessons learned and Design-for-Serviceability/Repairability feedback to NPI and future AI server platforms.
Own and improve performance against repair yield, first-time fix, MTTR, RMA turnaround and aging, repeat failure, NTF, corrective-action closure, and engineering-hold metrics.
Serve as a senior technical escalation point for critical customer and field issues.
Coordinate containment, failure reproduction, root-cause investigation, corrective action, validation, and effectiveness monitoring.
Lead technical reviews and communicate complex failures clearly to engineering, operations, customers, and executive leadership.
Work closely with Manufacturing, Quality, Test, Process Engineering, NPI, Program Management, Supply Chain, suppliers, and customer engineering organizations.
Translate field-return data into actionable improvements to manufacturing processes, test coverage, supplier quality, firmware, and product design.