Sr. Manufacturing Test Engineer – (Electro-Mechanical Systems)

Nextpower•Fremont, CA

1d•$170,000 - $190,000•Onsite

About The Position

Nextpower is seeking an experienced Senior Manufacturing Test Engineer to lead the transition of New Product Introduction (NPI) test solutions into stable, scalable, high-volume mass production test systems. This role is responsible for developing robust manufacturing test architectures, optimizing yield performance, and deploying standardized test systems across global Contract Manufacturers (CMs). The ideal candidate will drive Design for Test (DFT), oversee tester development through Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT), and ensure production test systems are capacity-optimized, change-controlled, and scalable to meet aggressive production yield and ramp targets.

Requirements

Bachelor’s or Master’s degrees in Electrical Engineering, Computer Engineering, or related field.
7+ years of experience in manufacturing test engineering within power electronics or related high-volume industries with minnimum 2 years of experience leading lab operations and/or managing technical team members.
Experience transitioning NPI programs into high-volume mass production.
Strong expertise in ICT, BFT, and SFT test methodologies.
Demonstrated experience scaling test operations across multiple global manufacturing sites.
Proficiency in at least one mainstream programming language: C#, Python, or C++.
Proficiency with test automation platforms such as Python, LabVIEW, and TestStand.
Ability to read schematics, identify test point requirements, and perform Design for Test (DFT) analysis.
Experience with Quality Management tools and methodologies: PFMEA, PPAP, APQP, QRQC.
Experience working with global contract manufacturers.
Excellent problem-solving, leadership, and cross-functional communication skills.

Responsibilities

Lead manufacturing test strategy development during NPI to ensure seamless transition into high-volume production environments.
Partner with NPI Test Design Engineering to drive Design for Test (DFT) improvements that enhance coverage, reduce cycle time, and improve yield.
Define and implement test coverage strategy across ICT, BFT, and SFT platforms to ensure robust product validation.
Collaborate with Test Design team and tester suppliers during tester development, qualification, FAT, and SOP phases.
Develop scalable test architectures capable of supporting high-volume manufacturing ramps and long-term production growth.
Analyze installed tester capacity and forecast future capacity needs to support demand allocation plans.
Optimize test cycle time, throughput, and station balancing to meet takt time and production targets with our CM partners.
Lead structured change management processes for ECO/ECN product revisions, firmware updates, and test program releases.
Evaluate impact of product updates on test coverage, cycle time, yield, and capacity, ensuring controlled global rollouts.
Drive continuous test program optimization to reduce cycle time, eliminate non-value-added steps, and improve yield while maintaining full coverage.
Maintain strict version control, validation, and regression testing processes for all test program changes prior to production release.
Deploy and qualify standardized test systems across multiple CMs to ensure global consistency.
Establish preventive maintenance, calibration, and long-term support strategies to ensure sustained tester performance and uptime.
Monitor and improve First Pass Yield (FPY) and Final Yield (FY) across global manufacturing sites.
Analyze test data to identify trends, systemic failures, and yield detractors, lead root cause and corrective action initiatives.
Manage tester inventory, spare parts strategy, and documentation including BOMs, schematics, block diagrams, and electrical drawings.
Maintain governance of test sequences and ensure compliance with quality management systems and regulatory standards.
Develop dashboards and executive-level reporting to provide real-time production and yield visibility.