Job DescriptionPosition Summary
The Manufacturing NPI Engineer is the bridge between Engineering and Production for new AC-DC power supplies and DC-DC converters, from introduction at our US factory through transfer to volume production at our Vietnam factory. You will own the manufacturing readiness of new products from early design review through pilot builds and release to production, and then lead their transfer and handover to the Vietnam team - ensuring each product can be built right the first time, at target cost, yield, and quality, and in compliance with required quality requirements.
In this role you will lead multiple concurrent NPI programs, serve as the manufacturing authority in design reviews, and help shape the site's NPI process and DFM standards. This is a hands-on, on-site role. You will spend significant time on the production floor and work closely with Design Engineering, Test Engineering, Quality, Supply Chain, and Production.
Key Responsibilities
New Product Introduction
- Act as manufacturing technical lead on cross-functional NPI teams, owning the manufacturing schedule, risk register, and cost, yield, and quality targets from concept through volume release.
- Plan and execute NPI builds (EVT/DVT/PVT) across multiple concurrent programs, coordinating materials, equipment, documentation, and resources.
- Represent manufacturing in stage-gate/design reviews; perform DFM/DFA, and DFT reviews of PCB layouts, BOM, Gerbers, Assembly Drawings and Mechanical designs, and drive design changes that improve manufacturability.
- Develop and own the production process flow, routings, and work instructions for SMT, through-hole, final assembly, test, and burn-in.
- Lead pilot-build reviews, capture lessons learned, and drive corrective actions to closure before release to volume.
- Define readiness criteria and sign off on transfer to production, including yield, cycle time, and documentation completeness.
- Develop and maintain site DFM/DFA design guidelines and NPI checklists; feed lessons learned back to design teams so they are applied to future products.
- Work with CM to validate manufacturing processes and quality requirements.
Production Transfer to Vietnam
- Own the transfer of released products from the US site to the Vietnam factory, working in partnership with the Vietnam receiving team to develop and execute the transfer plan, schedule, risk mitigation, and readiness milestones.
- Prepare and hand over a complete transfer package: MBOMs, drawings, routings, work instructions, PFMEAs, control plans, test procedures and software, fixtures, and lessons learned.
- Coordinate replication or shipment of tooling, fixtures, and test equipment, and verify equivalent setup and performance at the receiving site.
- Train the Vietnam engineering, test, quality, and production teams on each product and process, both on-site in Vietnam and remotely; confirm competency through training records and supervised builds.
- Lead transfer qualification builds (first article inspection, correlation of test results, process validation) and confirm the receiving site meets yield, quality, and cycle-time targets.
- Formally hand over ownership to the receiving team once production capability is demonstrated, and provide follow-up support to resolve post-transfer issues.
Process Development
- SMT & Through-Hole - Troubleshoot SMT and through-hole build issues that originate in the design (e.g., footprints, component spacing, thermal relief, polarity markings), and drive design fixes that make products easier to manufacture.
- Work with design engineers to ensure all agreed changes are documented through ECOs and reflected in updated schematics, PCB layouts, assembly drawings, and BOMs.
- Final Assembly - Develop assembly methods, sequences, and fixtures for open-frame and enclosed units, including PCBA-to-chassis integration, wire harness and cable routing, thermal interface and heatsink attachment, mechanical fastening and torque control, and labeling; drive mistake-proofing (poka-yoke) and line balance for efficient, repeatable builds.
- Test & Burn-In - Partner with Test Engineering to specify and validate functional/ATE test, hipot, ground-bond, and burn-in processes; develop or modify test fixtures and scripts as needed.
- Specify, justify (business case/ROI), procure, and qualify tooling, fixtures, and capital equipment; lead IQ/OQ/PQ process validation where required.
- Identify and drive product and process cost reductions to meet target cost for new products.
Quality & Compliance
- Create and maintain PFMEAs, control plans, and process validation documentation in line 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 (8D, 5-Why, Ishikawa) for NPI build issues, early-life failures, and customer returns; implement and verify corrective actions.
- Represent manufacturing engineering in internal, customer, and notified-body/regulatory audits.
Documentation & Systems
- Build and validate manufacturing BOMs, routings, and item setups in ERP/MRP; process ECOs/ECNs through PLM and manage product revision cut-ins.
- Monitor first-pass yield, scrap, and cycle time with SPC; drive continuous improvement using Lean and Six Sigma methods.
Mentoring, Training & Communication
- Mentor junior engineers and technicians, and serve as the go-to technical resource for production and engineering teams.
- Train production operators and leads on new products and processes.
- Communicate NPI status, risks, and mitigation plans clearly to cross-functional teams, management, and customers when required.
QualificationsRequired Qualifications
- Bachelor's degree in Electrical, Manufacturing, Mechanical, or Industrial Engineering - or equivalent hands-on experience (e.g., progression from senior manufacturing/test technician with demonstrated engineering-level responsibility).
- 6-8 years of manufacturing, process, or NPI engineering experience in electronics manufacturing, ideally power electronics.
- Proven track record of leading multiple NPI launches from design through volume production, including managing several programs at once.
- Experience transferring products between manufacturing sites, preferably to an overseas factory, including 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 (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 command of SPC and structured problem solving (8D, 5-Why).
- Hands-on IQ/OQ/PQ process validation experience in a regulated (medical) environment.
- Comfortable working safely around high-voltage test equipment and on an active production floor.
- Strong communication skills and the ability to influence and coordinate cross-functional teams.
Preferred Qualifications
- Familiarity with IEC 60601-1 production safety tests (hipot, leakage current, ground bond).
- Lean Six Sigma Green Belt (or higher); 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 a plus.
- Project management training or certification (e.g., PMP) and experience managing capital equipment projects.
Background & Knowledge Areas
Ideal candidates will bring practical understanding in the following areas:
- Power electronics fundamentals - switch-mode power conversion, isolation, creepage/clearance, thermal dissipation, and how component choices affect manufacturability and reliability.
- PCBA manufacturing - paste printing, placement, reflow and wave/selective soldering, and inspection (AOI, AXI); common defect modes and their causes.
- Mechanical & final assembly - assembly sequencing, fixture and jig design, torque and fastening methods, thermal interface materials, wire harnessing, and mistake-proofing for high-mix assembly.
- Test strategy - functional/ATE test coverage, safety testing, burn-in/ESS, and fixture design.
- Regulated quality systems - design transfer, change control, traceability, and documentation practices under ISO 13485.
- Lean manufacturing - line layout, takt time, standard work, and waste reduction for low-to-medium volume, high-mix production.
Tools & Systems
- ERP/MRP and PLM - [e.g., Oracle / SAP; Agile / Arena]
- Mechanical CAD - SolidWorks (required)
- PCB CAD / DFM - Altium Designer (preferred); Valor or equivalent Gerber/CAM tools
- Quality & analysis - PFMEA, control plans, SPC, Minitab
- Office - Microsoft 365 (Excel, PowerPoint, Project or equivalent)
Work Environment & Physical Requirements
- Based on-site at our US manufacturing facility (no remote work); regular time on the production floor.
- Work around electronic assembly equipment, chemicals (solder, flux), and high-voltage test stations; adherence to ESD and safety procedures required. PPE provided.
- Ability to stand/walk for extended periods and lift up to [25] lbs.
- Travel - 10-20% domestic and international travel, primarily to our Vietnam factory to lead product transfers and on-site training (trips may last 1-3 weeks), as well as to suppliers, customers, and other XP Power sites. A valid passport is required or must be obtained.
- Occasional flexibility to support builds outside standard hours.
Additional InformationXP Power provides a safe and healthy working environment that is stimulating and collaborative, where employees are empowered to make a real difference. We place our people at the heart of everything we do. We understand that if we provide our people with the ultimate experience, they will provide the ultimate experience to our customers.
We also offer a comprehensive benefits package including:
- 100% Employer Paid Medical, Dental and Vision Insurance for full-time Employee-only coverage; you share the cost of coverage for your dependents
- Company Paid Bonus (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 held throughout the year
- A Friendly Culture Where People Collaborate and Strive for Excellence
