Manufacturing NPI Test Engineer

XP Power•San Jose, CA

11h•Onsite

About The Position

The Manufacturing NPI Test Engineer bridges Test Engineering and Production for production testing of new power supplies and converters, from introduction at the US factory through transfer to volume production at the Vietnam factory. This hands-on, on-site role owns deployment of production testing for new products and improvements to existing tests, ensuring accurate, efficient testing that meets quality requirements. The engineer supports multiple concurrent NPI programs, leads production-test transfers to Vietnam, and serves as the primary production-floor test resource for existing products, improving yield, uptime, and test time. The role works closely with Test Engineering, Manufacturing NPI Engineering, Design Engineering, Quality, and Production. The position covers new-product production-test strategy and deployment; transfer planning, equipment replication, correlation, training, and handover to the Vietnam team; and sustaining production test through troubleshooting, equipment maintenance, test improvement, and failure analysis. Test methods include functional/ATE, safety testing, burn-in/ESS, and ICT/flying probe. The role also supports quality-system compliance, test validation, calibration, software revision control, traceability, documentation, reporting, and audits. The position is based on-site at the US manufacturing facility, with regular time on the production floor and 10–20% domestic and international travel, primarily to the Vietnam factory. Occasional flexibility to support builds and production test issues outside standard hours is expected. The role involves working around high-voltage test stations, burn-in equipment, electronic assembly equipment, and solder and flux, following ESD, high-voltage, and other safety procedures. PPE is provided. The job requires standing and walking for extended periods and lifting up to 25 lbs. A valid passport is required or must be obtained.

Requirements

6–8 years of test, production test, or test engineering experience in electronics manufacturing; power electronics experience is ideal.
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 testing.
Proficiency in at least one test-development platform: NI LabVIEW, NI TestStand, or Python; ability to read, debug, and modify test software.
Strong bench-instrument skills with programmable sources, electronic loads, oscilloscopes, power analyzers, and DMMs, plus instrument control using GPIB, USB, LAN, and 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 component-level electronic troubleshooting skills.
Working knowledge of ISO 9001; experience in ISO 13485 or another regulated medical environment, including test-method validation and test-software change control.
Strong command of structured problem-solving methods such as 8D and 5-Why, SPC, and MSA/Gage R&R.
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.
Comfort with on-site work at the US manufacturing facility and regular production-floor work.
Ability to stand and walk for extended periods and lift up to 25 lbs.
Valid passport or ability to obtain one; willingness to travel 10–20% domestically and internationally, primarily to Vietnam.
Occasional flexibility to support builds and production test issues outside standard hours.

Nice To Haves

Bachelor's degree in Electrical Engineering, Electronics Engineering, or Computer Engineering, or equivalent hands-on experience such as progression from senior test technician with demonstrated engineering-level responsibility.
Experience testing AC-DC power supplies and/or DC-DC converters, including switch-mode topologies, protection circuits, efficiency, and thermal performance.
Familiarity with IEC 60601-1 and IEC 62368-1 production safety tests, including hipot, leakage current, and ground bond.
Proficiency in more than one of LabVIEW, TestStand, and Python; NI certification such as CLD or CTD is a plus.
Working experience with SolidWorks for test-fixture design and review of 3D models and drawings.
Experience with ICT/flying-probe platforms such as Keysight, Teradyne, Takaya, or SPEA.
Hands-on IQ/OQ/PQ and test-method validation experience in a regulated medical environment.
Lean Six Sigma Green Belt or higher and proficiency with Minitab.
Experience with test-data management, MES, or databases such as SQL for traceability and reporting.
Experience working with manufacturing teams in Southeast Asia; Vietnamese language skills are a plus.
Practical understanding of power-electronics fundamentals, test strategy and coverage, measurement science, fixture design, regulated quality systems, and production-test operations.
Familiarity with ERP/MRP and PLM systems such as Oracle, SAP, Agile, or Arena; Microsoft 365, including Excel, PowerPoint, and Project or equivalent.

Responsibilities

Represent production test on cross-functional NPI teams and provide design-for-test input during design reviews.
Partner with Test Engineering to define production-test strategies for new products across ICT/flying probe, functional/ATE, hipot/safety, and burn-in/ESS.
Collaborate on development of test stations, fixtures, and software, and review test specifications and procedures for production readiness, test time, and operator usability.
Own installation, debugging, and release of production test stations, fixtures, test programs, and limits for new products.
Validate production tests using 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; analyze test data, identify failure trends, and drive root cause with Design and Test Engineering.
Define test-readiness criteria and approve test release to production, including yield, test time, documentation, and operator training.
Develop and maintain test work instructions, procedures, and operator troubleshooting guides.
Plan and lead transfer of released-product production testing from the US site to the Vietnam factory, including schedules, risk mitigation, and readiness milestones.
Prepare test transfer packages containing specifications, procedures, revision-controlled software and limits, station configurations, fixture drawings and bills of materials, calibration and maintenance requirements, and troubleshooting information.
Coordinate replication or shipment of test stations, fixtures, and burn-in equipment; verify equivalent setup, configuration, and calibration at the receiving site.
Lead US-to-Vietnam test correlation and confirm the receiving site meets test yield, test time, and quality targets.
Train Vietnam test engineers and technicians in test operation, debugging, maintenance, and failure analysis; confirm competency through records and supervised builds.
Formally hand over test ownership when the receiving team demonstrates capability and provide follow-up support for post-transfer issues.
Troubleshoot tester, fixture, and software issues for existing products to minimize production-line downtime.
Monitor test yield, false failures, retest rates, and test time; improve test through limit optimization, fixture improvements, software updates, and test-time reduction.
Deploy tester updates and improvements 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 schedules and records.
Support failure analysis of test failures, early-life failures, and customer returns, and share findings with Design, Test Engineering, and Manufacturing.
Identify, justify with a business case or ROI, specify, procure, and qualify test equipment and automation improvements.
Deploy and support functional testing using programmable AC/DC sources, electronic loads, power analyzers, oscilloscopes, and DMMs; test parameters include efficiency, regulation, ripple and noise, transient response, start-up timing, and protection features.
Deploy and maintain hipot, insulation-resistance, ground-bond, and leakage-current tests in accordance with IEC 60601-1 and IEC 62368-1, including daily safety-tester verification.
Support burn-in racks, load banks, and thermal cycling; work with Quality to define and optimize burn-in and ESS profiles.
Support PCBA-level ICT/flying-probe test programs and fixtures, including coverage review, debugging, and false-call reduction.
Provide test input 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 calibration, test-software version control, and serial-level traceability of test records meet medical-quality requirements.
Lead root-cause analysis using 8D, 5-Why, and Ishikawa methods for test escapes and test-related nonconformances; implement and verify corrective actions.
Represent production test in internal, customer, and notified-body or regulatory audits.
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 performance and maintain yield, failure Pareto, and test-time reporting.
Mentor test technicians and junior engineers and serve as a production-test resource for production and engineering teams.
Train production operators and test technicians on test stations and procedures, including safe operation of high-voltage equipment.
Communicate test status, risks, and mitigation plans to cross-functional teams, management, and customers when required.

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 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 throughout the year.
Safe, healthy, stimulating, and collaborative working environment.