Lead Manufacturing Engineer, Test

Mach Industries•Huntington Beach, CA

1d•$140,000 - $180,000•Onsite

About The Position

As Lead Manufacturing Engineer, Test, you will be the technical owner of production testing across all products and subsystems. This scope includes PCB flashing and configuration, component and subassembly test, end-of-line (EOL) system functional test, and final acceptance. You will define what gets tested, where, and how. You will design, source, and launch the stations, fixtures, software, and data flows that make it work at rate. You will work across Product Engineering, Firmware, Manufacturing Engineering, Controls, Quality, Supply Chain, and Operations so that design intent becomes repeatable, high-coverage, data-rich production testing. This is a hands-on technical role with direct reports. You will set the technical direction for your test area and guide the engineers, technicians, and integrators working on it. You will also be on the floor bringing up stations, debugging failures, and keeping hardware moving.

Requirements

Bachelor's degree in Electrical, Mechanical, Aerospace, Computer, or Manufacturing Engineering, or a related technical field
7+ years of experience in manufacturing test, test engineering, or production validation in aerospace, automotive, electronics, or comparable complex hardware environment
Demonstrated experience taking production test systems from concept through FAT/SAT, launch, and rate production
Experience implementing production PCB flashing and configuration for embedded electronics, including firmware image control and programming verification
Proficiency in at least one test development environment, such as Python, LabVIEW/TestStand, or C#
3D CAD experience for fixture and test interface design (Siemens NX preferred)
Strong understanding of test strategy, test coverage, limit setting, MSA/Gage R&R, and statistical data analysis
Experience with structured problem-solving (8D, 5-Why, fishbone, fault tree analysis)
Experience writing equipment specifications and managing external vendors

Nice To Haves

Production test experience in aerospace and defense, especially UAS, munitions, avionics, or propulsion
Experience with production programming tools, such as SEGGER J-Link/Flasher, Data I/O, BPM Microsystems, or similar, and with programming through ICT or boundary scan
Experience with secure provisioning and key injection, signed firmware, and protecting controlled firmware images on the factory floor
Experience developing leak test profiles and methods (pressure decay, mass flow, helium/tracer gas)
Experience with turbine, jet engine, or other propulsion acceptance testing
Experience with PCBA and harness test methods: ICT, flying probe, boundary scan (JTAG), functional test, and automated harness testers (Cirris, DIT-MCO, or similar)
Experience with vehicle and embedded communication protocols, such as CAN, RS-422/485, UART, SPI/I2C, Ethernet, or MAVLink
Experience with RF test equipment and methods (VNA, spectrum analyzer, datalink and GNSS checkout)
Experience with environmental stress screening, burn-in, or HALT/HASS
Electrical design experience with tools such as EPLAN or similar
Familiarity with AS9100, MIL-STD-810, and MIL-STD-461
Lean or Six Sigma experience, with statistical tools such as Minitab or JMP
Experience standing up new test capability in an early-stage or high-growth environment
Active U.S. security clearance, or the ability to obtain one

Responsibilities

Own production test strategy and execution for assigned products and subsystems, from incoming and component test through subassembly test, EOL functional test, rework and retest, and final acceptance.
Turn product requirements, design intent, and DFMEA/PFMEA risks into test requirements, coverage maps, test limits, and pass/fail criteria.
Author and own the Design for Test (DFT) section of the Manufacturing Engineering DFM/A Guide. Write guidelines for test access and test points, programming and debug access, connector and harness access, built-in self-test and diagnostics, calibration provisions, and serialization and traceability. Keep the section current as products and test methods change, and use it in design reviews so Product Engineering designs for testability from the start.
Own the PCB flashing strategy. Decide where in the build flow boards and modules get programmed (at the supplier, at board-level test, or at system integration). Select programming methods and equipment, such as JTAG/SWD, bootloader over USB, CAN, or serial, and gang programmers, based on cycle time, cost, and rate.
Develop and launch production flashing stations and processes. Partner with Firmware Engineering to release production firmware images under configuration control. Own image versioning, checksum and readback verification, unit-specific configuration (serial numbers, calibration data, and keys or secure provisioning), and re-flash processes for engineering changes and rework.
Develop, validate, and launch production test stations and fixtures, such as: Avionics and PCBA functional test, Wire harness continuity and hipot test, Leak and pressure decay test profiles for fuel, pneumatic, and sealed assemblies, Turbojet engine acceptance testing, RF, datalink, and GPS checkout, Sensor and IMU calibration, Control surface and actuator verification, Full-system EOL functional test.
Design or specify test fixtures and interfaces in 3D CAD. Develop or review test station electrical schematics and integrator designs.
Write equipment and process specifications, assess vendor and integrator capabilities, and make data-driven sourcing and make-vs-buy recommendations.
Lead vendors and integrators through design reviews, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), installation, and commissioning.
Validate test systems before release using MSA/Gage R&R, golden-unit and limit-sample correlation, and guardband analysis.
Run Designs of Experiments (DOEs) to optimize test methods, improve detection sensitivity, and reduce cycle time without losing coverage.
Drive test readiness for new product introductions, design changes, and line bring-ups, including validation plans, cutover plans, and issue containment.
Improve the failure feedback loop: fault isolation, diagnostic coverage, troubleshooting guides, retest logic, and fast feedback to design, suppliers, and process owners.
Define test and programming requirements for suppliers and support customer and government acceptance activities, including Acceptance Test Procedures (ATPs) and first article testing.
Act as technical lead on test projects. Guide and review the work of engineers, technicians, and integrators, and mentor junior engineers.
Support operations with training, documentation, and work instructions, and be the first responder to test station and test failure issues on the floor.