Senior Industrial Engineer–AI Server RMA (Field Repair) Operation

Foxconn Industrial Internet - FII•Houston, TX

12d

About The Position

This position optimizes the end-to-end Return Material Authorization (RMA) and field-repair operation, including product receiving, triage, diagnostics, disassembly, component repair or replacement, liquid-cooling service, system integration, testing, quality verification, packaging, and return-to-customer flow. The Senior Industrial Engineer uses data-driven methods to improve throughput, turnaround time, labor productivity, capacity, quality, ergonomics, and operational cost while ensuring processes are scalable, safe, traceable, and repeatable. The role designs and maintains RMA workflows and standard repair routes, performs industrial engineering and capacity-planning analyses, and leads Lean and continuous-improvement activities. It also develops repair-area layouts and workstations, establishes operational dashboards and metrics, and partners with IT/MES teams to improve routing, traceability, data collection, defect coding, and electronic work instructions. The position works cross-functionally with Operations, Manufacturing Engineering, Quality, Test, Materials, Planning, IT/MES, EHS, and engineering teams.

Requirements

Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, Systems Engineering, or a related technical field.
Typically 5+ years of relevant industrial or manufacturing engineering experience, including ownership of complex production or repair processes.
Demonstrated experience with time studies and labor standards.
Demonstrated experience with capacity and manpower modeling.
Demonstrated experience with line or cell balancing.
Demonstrated experience with factory or workstation layout.
Demonstrated experience with standardized work.
Demonstrated experience with Lean manufacturing.
Demonstrated experience with root-cause analysis and continuous improvement.
Strong data-analysis capability using Microsoft Excel and similar analytical or reporting tools.
Experience working cross-functionally with Operations, Manufacturing Engineering, Quality, Test, Materials, Planning, IT/MES, and EHS.
Ability to operate effectively in a fast-paced environment with changing volume, priorities, and technical requirements.
Strong written, verbal, analytical, and technical presentation skills.

Nice To Haves

Experience with server, rack, storage, networking, electronics, semiconductor, or other high-tech manufacturing or repair environments.
Experience supporting RMA, depot repair, field service, failure analysis, or reverse logistics.
Knowledge of AI/HPC server architecture and high-density compute environments.
Experience with MES, ERP, WMS, Power BI, SQL, Minitab, AutoCAD/Factory Design, or simulation tools.
Lean Six Sigma Green Belt or Black Belt certification.
Familiarity with ISO 9001, ESD controls, PFMEA, Control Plans, and high-tech manufacturing quality systems.

Responsibilities

Design, optimize, and maintain end-to-end RMA workflows from receiving and triage through diagnosis, repair, testing, final inspection, and shipment.
Establish standard repair routes for common server and liquid-cooling failure modes.
Identify bottlenecks, queue time, rework loops, excessive handling, and non-value-added activities.
Develop processes that can handle variable RMA demand, product configurations, and repair complexity.
Support field-repair requirements and translate field service issues into improved factory repair processes.
Perform time studies, work measurement, line balancing, capacity modeling, staffing analysis, and workstation optimization.
Establish engineered labor standards and manpower requirements by repair type and product family.
Model capacity for receiving, diagnostics, repair, coolant service, testing, burn-in, packaging, and shipment.
Develop scenarios for demand ramps and changing RMA volumes; analyze WIP and queue levels and recommend capacity buffers.
Drive productivity improvements while maintaining product quality and technician safety.
Optimize service processes involving cooling components and systems, coolant handling, leak inspection, flushing and filling, and pressure/leak testing, where applicable.
Work with EHS and engineering teams to ensure safe handling of heavy, high-value server assemblies and cooling systems.
Incorporate ergonomics and material-handling solutions for racks, trays, servers, and repair fixtures.
Lead Lean, Kaizen, 5S, Value Stream Mapping, DMAIC, and structured problem-solving activities.
Apply Pareto analysis, 5-Why, Ishikawa/Fishbone, FMEA, SPC, and root-cause analysis to operational problems.
Reduce waste associated with waiting, movement, transportation, inventory, overprocessing, defects, and rework.
Develop standardized work and visual management for critical RMA processes.
Facilitate cross-functional improvement workshops and drive actions through closure.
Develop and maintain layouts for repair cells, diagnostic stations, test areas, WIP locations, coolant-service areas, material supermarkets, and finished-goods staging.
Define space, equipment, tooling, utilities, ESD, material-flow, and ergonomic requirements for new or expanding operations.
Optimize factory flow to minimize travel distance and unnecessary product handling.
Support introduction and qualification of new workstations, fixtures, tooling, and automation.
Develop dashboards and operating metrics for RMA turnaround time, units repaired per labor hour, repair/retest rate, WIP and aging, queue time, capacity utilization, labor efficiency, and on-time completion.
Use production data to identify constraints and prioritize improvements based on operational and financial impact.
Partner with IT/MES teams to improve repair routing, traceability, data collection, defect coding, and electronic work instructions.