Test Engineer

We are seeking a dynamic and detail-oriented Test Engineer to join our team. The Test Engineer bridges product design, manufacturing, quality, and global engineering teams by defining robust test strategies, developing automated test solutions, validating test performance, and ensuring reliable high-volume production testing.

This role requires practical expertise in electrical measurements, manufacturing processes, statistical analysis, and troubleshooting of magnetic components.

Essential Duties and Responsibilities Other duties may be assigned.

Test Development and Industrialization

· Define production test strategies, specifications, acceptance limits, and test sequences for magnetic products.

· Develop, implement, validate, and maintain automated and semi-automated production test systems.

· Establish testing methodologies for inductance, DCR, turns ratio, impulse, Hi-Pot, and related electrical characteristics.

· Support test-fixture, connector, tooling, and interface design to ensure repeatable measurements.

· Create test instructions, set up documentation, troubleshooting guides, and operator training materials.

· Support prototype, pilot-build, qualification, and mass-production phases of new products.

Manufacturing and Process Support

· Work closely with Process Engineering to integrate reliable test operations into manufacturing process flows.

· Identify and eliminate test-related bottlenecks, false failures, measurement variation, and yield losses.

· Support production ramp-up, factory start-up activities, and manufacturing transfers.

· Troubleshoot production test failures and coordinate technical actions with manufacturing, quality, suppliers, and product-development teams.

· Participate in manufacturing-readiness reviews and production-qualification activities.

Test Validation and Measurement-System Analysis

· Perform measurement-system analyses, including MSA and GR&R studies, for production test equipment.

· Conduct test-correlation studies between equipment, fixtures, operators, and global production sites.

· Establish test-system capability requirements and monitor performance through SPC and Cpk analysis.

· Validate test limits and guard bands to balance product quality, customer requirements, and manufacturing yield.

· Support reliability testing, failure analysis, root-cause investigations, and corrective/preventive actions.

Continuous Improvement and Cost Optimization

· Apply DOE and statistical methods to optimize test processes, measurement repeatability, cycle time, and test coverage.

· Improve test efficiency, equipment utilization, productivity, and production capacity.

· Support cost-estimation activities by defining test cycle times, equipment requirements, and labor content.

· Identify opportunities for automation, fixture improvements, error-proofing, and test-cost reduction.

· Maintain technical documentation in accordance with SUMIDA quality and manufacturing standards.

Global Collaboration

· Coordinate test-engineering activities with teams in the United States, Japan, China, and other SUMIDA manufacturing locations.

· Support the transfer, replication, and validation of test equipment and methodologies between global sites.

· Communicate technical test requirements, results, risks, and corrective actions clearly to internal and external stakeholders.

· Provide hands-on support during product transfers, customer audits, factory start-ups, and production ramp-ups as required.

· Bachelor’s degree, associate degree, technical diploma, or equivalent practical experience in Electrical Engineering, Mechanical Engineering, Engineering Technology, Electronics Engineering, Manufacturing Engineering, or a related technical field.

· Several years of experience in test engineering, manufacturing engineering, quality engineering, industrialization, or electronics production; experience in transformer, inductor, magnetic-component, or electronics manufacturing is preferred.

· Practical experience with electrical production testing, including inductance and LCR measurement, DCR measurement, turns-ratio testing, impulse testing, and Hi-Pot or dielectric-withstand testing.

· Experience developing, maintaining, or supporting automated production test systems and test fixtures.

· Strong knowledge of statistical and quality-engineering tools, including SPC, Cpk, MSA, GR&R, DOE, PFMEA, control plans, root-cause analysis, and CAPA.

· Ability to interpret product drawings, electrical specifications, test requirements, and manufacturing documentation.

· Proficiency in Microsoft Office; experience with SolidWorks or comparable 3D CAD software is an advantage.

· Strong analytical, troubleshooting, documentation, and project-coordination skills.

· Professional English communication skills; Japanese and/or Chinese language capability is an advantage.

Preferred Qualifications

· Experience with transformer or inductor manufacturing processes, including winding, assembly, impregnation, molding, and final electrical testing.

· Experience with NPI, product qualification, manufacturing transfer, or factory start-up projects.

· Familiarity with manufacturing cost estimation, capacity planning, and test-cycle-time optimization.

· Experience with test data collection, traceability systems, production databases, or automated data analysis.

· Hands-on experience designing fixtures, tooling, and poka-yoke solutions for production environments.

Pulled from the full job description

• Referral program
• Professional development assistance
• Tuition reimbursement
• 401(k)
• Health insurance
• 401(k) matching
• Paid time off, * 401(k)
• 401(k) matching
• Dental insurance
• Employee assistance program
• Health insurance
• Health savings account
• Life insurance
• Paid time off
• Professional development assistance
• Referral program
• Tuition reimbursement
• Vision insurance