Senior Test Engineer PCBA Industrialization (Python+Labview)

Job Description

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.
• Required QualificationsEducation & Experience
  
• Bachelors Degree in Electrical Engineering, Computer Engineering, Mechatronics, or a highly related technical field.
• 6 to 14+ years of hands-on experience as a Manufacturing Test Engineer, with at least 6 years dedicated to End-of-Line (EOL) testing in an automotive, EVSE, battery, or high-power electronics environment.
• Experience working directly with high-voltage AC (up to 480V three-phase) or high-voltage DC (up to 1000V+) test systems.
• Technical Skills
  
• Software: Highly proficient in test development environments, specifically NI TestStand/LabVIEW and/or Python for hardware-in-the-loop (HIL) automation.
• Protocols & Standards: Solid understanding of EV charging physical layers and messaging standards (e.g., J1772, ISO 15118, DIN 70121, OCPP).
• Equipment: Direct experience configuring and controlling programmable power supplies, electronic loads (E-Loads), digital oscilloscopes, and safety testers.
• Safety & Compliance: Familiarity with high-voltage lab safety guidelines, NFPA 70E compliance, and UL standards relevant to EVSE (e.g., UL 2202, UL 2594, UL 2231).
• Soft Skills
  
• Strong analytical, data-driven mindset with the ability to draw root-cause conclusions from complex test logs.
• Excellent collaborative communication skills to interface effectively with firmware developers, hardware engineers, and production operators.

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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