Manufacturing NPI Engineer

XP Power•San Jose, CA

1d•$130,000 - $140,000•Onsite

About The Position

The Manufacturing NPI Engineer is the bridge between Engineering and Production for new AC-DC power supplies and DC-DC converters, from introduction at the US factory through transfer to volume production at the Vietnam factory. The role owns manufacturing readiness from early design review through pilot builds and production release, then leads product transfer and handover to the Vietnam team to ensure products meet target cost, yield, quality, and applicable requirements. This hands-on, on-site role leads multiple concurrent NPI programs, represents manufacturing in design reviews, and helps develop site NPI processes and DFM standards. It works closely with Design Engineering, Test Engineering, Quality, Supply Chain, and Production, with regular time on the production floor. The position also develops manufacturing processes for SMT, through-hole, final assembly, test, and burn-in; manages quality and compliance activities; maintains manufacturing documentation and systems; and mentors and trains engineers, technicians, and production staff. The role includes 10–20% domestic and international travel, primarily to the Vietnam factory, and occasional flexibility to support builds outside standard hours.

Requirements

Bachelor's degree in Electrical, Manufacturing, Mechanical, or Industrial Engineering, or equivalent hands-on experience demonstrating engineering-level responsibility.
6–8 years of manufacturing, process, or NPI engineering experience in electronics manufacturing; power electronics experience is ideal.
Demonstrated success leading multiple NPI launches from design through volume production and managing several programs concurrently.
Experience transferring products between manufacturing sites, preferably to an overseas factory, and training receiving teams to full production capability.
Strong hands-on experience with SMT and through-hole PCBA processes, final assembly, and functional test/burn-in.
Working knowledge of ISO 9001 and IPC-A-610; experience in an ISO 13485 or other regulated medical environment.
Proficiency with ERP/MRP and PLM systems for BOMs, routings, and engineering change control.
Ability to read schematics, PCB layouts, Gerber data, and mechanical drawings, including GD&T.
Working experience with SolidWorks for reviewing and modifying 3D models, assemblies, and drawings, and designing assembly fixtures and jigs.
Experience leading PFMEAs, control plans, and work instructions; strong knowledge of SPC and structured problem-solving methods such as 8D and 5-Why.
Hands-on IQ/OQ/PQ process-validation experience in a regulated medical environment.
Ability to work safely around high-voltage test equipment and on an active production floor.
Strong communication skills and ability to influence and coordinate cross-functional teams.
Ability to stand and walk for extended periods and lift up to 25 lbs.
Valid passport or ability to obtain one for required travel.
On-site work at the US manufacturing facility; remote work is not available.

Nice To Haves

Familiarity with IEC 60601-1 production safety tests, including hipot, leakage current, and ground bond.
Lean Six Sigma Green Belt or higher and proficiency with Minitab.
Experience with Altium Designer for reviewing schematics and PCB layouts; familiarity with Valor or similar CAM tools for DFM analysis.
IPC-A-610 certification (CIS).
Experience working with manufacturing teams in Southeast Asia; Vietnamese language skills are a plus.
Project management training or certification, such as PMP, and experience managing capital-equipment projects.
Practical understanding of power electronics fundamentals, PCBA manufacturing, mechanical and final assembly, test strategy, regulated quality systems, and Lean manufacturing.

Responsibilities

Lead manufacturing activities on cross-functional NPI teams, owning schedules, risk registers, and cost, yield, and quality targets from concept through volume release.
Plan and execute EVT, DVT, and PVT builds across concurrent programs, coordinating materials, equipment, documentation, and resources.
Represent manufacturing in stage-gate and design reviews; perform DFM/DFA and DFT reviews of PCB layouts, BOMs, Gerbers, assembly drawings, and mechanical designs, and drive manufacturability improvements.
Develop and own production process flows, routings, and work instructions for SMT, through-hole, final assembly, test, and burn-in.
Lead pilot-build reviews, document lessons learned, and drive corrective actions to completion before volume release.
Define production-readiness criteria and approve transfer based on yield, cycle time, and documentation completeness.
Develop and maintain site DFM/DFA guidelines and NPI checklists and feed lessons learned back to design teams.
Work with contract manufacturers to validate manufacturing processes and quality requirements.
Own transfer of released products from the US site to the Vietnam factory, including transfer plans, schedules, risk mitigation, and readiness milestones.
Prepare and hand over transfer documentation and assets, including MBOMs, drawings, routings, work instructions, PFMEAs, control plans, test procedures and software, fixtures, and lessons learned.
Coordinate tooling, fixture, and test-equipment replication or shipment, and verify equivalent setup and performance at the receiving site.
Train Vietnam engineering, test, quality, and production teams on products and processes, and confirm competency through records and supervised builds.
Lead transfer qualification builds, including first article inspection, test-result correlation, and process validation; confirm yield, quality, and cycle-time targets.
Formally hand over product ownership after production capability is demonstrated and provide follow-up support for post-transfer issues.
Troubleshoot design-originated SMT and through-hole build problems and work with design engineers to document agreed changes through ECOs and update product documentation.
Develop final-assembly methods, sequences, and fixtures; improve mistake-proofing and line balance for repeatable builds.
Partner with Test Engineering to specify and validate functional/ATE test, hipot, ground-bond, and burn-in processes; develop or modify fixtures and scripts as needed.
Specify, justify, procure, and qualify tooling, fixtures, and capital equipment, and lead IQ/OQ/PQ validation where required.
Identify and implement product and process cost reductions to meet target costs.
Create and maintain PFMEAs, control plans, and process-validation documentation in accordance with ISO 9001 and ISO 13485 requirements.
Apply IPC-A-610 workmanship standards and support production of medical power supplies certified to IEC 60601-1.
Lead root-cause analysis for NPI build issues, early-life failures, and customer returns, and implement and verify corrective actions.
Represent manufacturing engineering in internal, customer, and notified-body or regulatory audits.
Build and validate manufacturing BOMs, routings, and item setups in ERP/MRP; process ECOs/ECNs through PLM and manage revision cut-ins.
Monitor first-pass yield, scrap, and cycle time using SPC, and drive continuous improvement using Lean and Six Sigma methods.
Mentor junior engineers and technicians; train production operators and leads on new products and processes.
Communicate NPI status, risks, and mitigation plans to cross-functional teams, management, and customers when required.
Travel domestically and internationally, primarily to the Vietnam factory, for product transfers and on-site training; occasional trips may last 1–3 weeks.
Follow ESD and safety procedures while working on the production floor and around assembly equipment, chemicals, and high-voltage test stations.

Benefits

100% employer-paid medical, dental, and vision insurance for full-time employee-only coverage; employees share dependent coverage costs.
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.
Friendly, collaborative culture.