Senior Engineer II, Industrialization PCBA and Product Test

1.

EOL Test System Design & Commissioning


* Design, build, and validate automated EOL test fixtures (both AC and high-power DC test benches) using programmable electronic loads, power analyzers, grid simulators, and EV emulators.


* Develop and maintain EOL test execution scripts and sequences using NI LabVIEW, TestStand, Python, or PLC architectures.


* Implement and manage safety-critical systems for high-voltage and high-current testing environments, including interlocks, light curtains, emergency stop (E-stop) circuits, and Lockout/Tagout (LOTO) protocols.

2.

Functional & Safety Testing Integration


* Integrate mandatory electrical safety checks into the automated test cycle, including dielectric withstand (Hi-Pot), insulation resistance, and ground continuity testing.


* Automate validation of critical safety devices such as CCID (Charge Circuit Interrupting Device) ground fault detection and overcurrent protection.


* Automate the functional validation of communication interfaces, including vehicle-to-charger handshakes (CCS/NACS physical layers via PLC/PWM) and network interfaces (OCPP via Ethernet, Wi-Fi, or cellular).

3.

Diagnostics & Root Cause Analysis


* Troubleshoot complex test stand issues involving hardware, firmware, or test software to minimize line downtime.


* Establish robust processes for diagnosing units that fail EOL testing; define clear "Rework" instructions and verify the effectiveness of those repairs.


* Use diagnostic and network tracing tools (e.g., CANalyzer, CANoe, Wireshark) to analyze communication trace logs when troubleshooting vehicle-to-charger signaling failures.

4.

Continuous Improvement & Data Traceability


* Integrate EOL test systems with the factory Manufacturing Execution System (MES) and database architectures (SQL) for complete serial-number-level test result traceability.


* Monitor first-pass yield (FPY) and cycle times at EOL, utilizing statistical data analysis to isolate and eliminate false failures and process bottlenecks.


* Lead the transfer of new product EOL test requirements from R&D (Design Verification Testing) to high-volume manufacturing lines.

Preferred Qualifications


* Experience with unified EV/EVSE functional test platforms (e.g., Keysight, Chroma, or similar systems).


* Direct experience with CTEP / NTEP metrology and calibration requirements for commercial EVSE billing accuracy.


* Certification in Lean Six Sigma (Green Belt or Black Belt) and experience with Gauge R&R studies on test equipment.

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