{"id":3106766,"url":"https://alion.io/job/xp-power-manufacturing-npi-engineer","title":"Manufacturing NPI Engineer","company":{"id":8620,"name":"XP Power","domain":"xppower.com","url":"https://alion.io/company/xppower","size_band":"201-500","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"SmartRecruiters","truth_index":{"grade":"B","score":78,"open_postings":15,"ghost_share":0,"stale_share":0.867,"repost_share":0,"time_to_fill_p50_days":46,"computed_at":"2026-10-25T05:49:26Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["San Jose, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":{"min":130000,"max":140000,"currency":"USD","period":"year","gross":null,"usd_annual":140000},"salary_estimate":null,"experience_years_min":6,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"GD&T","optional":false},{"name":"IEC 60601","optional":false},{"name":"ISO 13485","optional":false},{"name":"SolidWorks","optional":false},{"name":"Statistical Process Control","optional":false},{"name":"Agile","optional":true},{"name":"Altium Designer","optional":true},{"name":"FMEA","optional":true},{"name":"Minitab","optional":true}],"status":"live","first_seen_at":"2026-10-22T17:24:20Z","employer_posted_date":"2026-10-22","last_verified_at":"2026-10-25T16:16:08Z","board_verified":true,"closed_at":null,"days_open":3,"trust":{"level":"ok","repost_count":null,"flags":[],"days_open":3},"description":"XP Power is a major supplier of critical power conversion technology to the medical, technology, industrial, and defence markets. We are a fast-growing company listed on the London Stock Exchange. We are looking for self-motivated professionals who thrive in dynamic environments. We are proud of and committed to our culture that values Customer Focus, Flexibility, Knowledge, Speed, and Integrity. Joining our team means you will work in a high performing global company where employees collaborate and strive for excellence.\n Position Summary\nThe 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.\nIn 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.\nKey Responsibilities\nNew Product Introduction\nAct 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.\nPlan and execute NPI builds (EVT/DVT/PVT) across multiple concurrent programs, coordinating materials, equipment, documentation, and resources.\nRepresent 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.\nDevelop and own the production process flow, routings, and work instructions for SMT, through-hole, final assembly, test, and burn-in.\nLead pilot-build reviews, capture lessons learned, and drive corrective actions to closure before release to volume.\nDefine readiness criteria and sign off on transfer to production, including yield, cycle time, and documentation completeness.\nDevelop and maintain site DFM/DFA design guidelines and NPI checklists; feed lessons learned back to design teams so they are applied to future products.\nWork with CM to validate manufacturing processes and quality requirements.\nProduction Transfer to Vietnam\nOwn 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.\nPrepare and hand over a complete transfer package: MBOMs, drawings, routings, work instructions, PFMEAs, control plans, test procedures and software, fixtures, and lessons learned.\nCoordinate replication or shipment of tooling, fixtures, and test equipment, and verify equivalent setup and performance at the receiving site.\nTrain 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.\nLead transfer qualification builds (first article inspection, correlation of test results, process validation) and confirm the receiving site meets yield, quality, and cycle-time targets.\nFormally hand over ownership to the receiving team once production capability is demonstrated, and provide follow-up support to resolve post-transfer issues.\nProcess Development\n 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.\nWork with design engineers to ensure all agreed changes are documented through ECOs and reflected in updated schematics, PCB layouts, assembly drawings, and BOMs.\n 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.\n 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.\nSpecify, justify (business case/ROI), procure, and qualify tooling, fixtures, and capital equipment; lead IQ/OQ/PQ process validation where required.\nIdentify and drive product and process cost reductions to meet target cost for new products.\nQuality & Compliance\nCreate and maintain PFMEAs, control plans, and process validation documentation in line with ISO 9001 and ISO 13485 requirements.\nApply IPC-A-610 workmanship standards and support production of medical power supplies certified to IEC 60601-1.\nLead root cause analysis (8D, 5-Why, Ishikawa) for NPI build issues, early-life failures, and customer returns; implement and verify corrective actions.\nRepresent manufacturing engineering in internal, customer, and notified-body/regulatory audits.\nDocumentation & Systems\nBuild and validate manufacturing BOMs, routings, and item setups in ERP/MRP; process ECOs/ECNs through PLM and manage product revision cut-ins.\nMonitor first-pass yield, scrap, and cycle time with SPC; drive continuous improvement using Lean and Six Sigma methods.\nMentoring, Training & Communication\nMentor junior engineers and technicians, and serve as the go-to technical resource for production and engineering teams.\nTrain production operators and leads on new products and processes.\nCommunicate NPI status, risks, and mitigation plans clearly to cross-functional teams, management, and customers when required.\n Required Qualifications\nBachelor'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).\n6-8 years of manufacturing, process, or NPI engineering experience in electronics manufacturing, ideally power electronics.\nProven track record of leading multiple NPI launches from design through volume production, including managing several programs at once.\nExperience transferring products between manufacturing sites, preferably to an overseas factory, including training receiving teams to full production capability.\nStrong hands-on experience with SMT and through-hole PCBA processes, final assembly, and functional test/burn-in.\nWorking knowledge of ISO 9001 and IPC-A-610; experience in an ISO 13485 or other regulated (medical) environment.\nProficiency with ERP/MRP and PLM systems for BOMs, routings, and engineering change control.\nAbility to read schematics, PCB layouts, Gerber data, and mechanical drawings (GD&T).\nWorking experience with SolidWorks for reviewing and modifying 3D models, assemblies, and drawings, and designing assembly fixtures and jigs.\nExperience leading PFMEAs, control plans, and work instructions; strong command of SPC and structured problem solving (8D, 5-Why).\nHands-on IQ/OQ/PQ process validation experience in a regulated (medical) environment.\nComfortable working safely around high-voltage test equipment and on an active production floor.\nStrong communication skills and the ability to influence and coordinate cross-functional teams.\nPreferred Qualifications\nFamiliarity with IEC 60601-1 production safety tests (hipot, leakage current, ground bond).\nLean Six Sigma Green Belt (or higher); proficiency with Minitab.\nExperience with Altium Designer for reviewing schematics and PCB layouts; familiarity with Valor or similar CAM tools for DFM analysis.\nIPC-A-610 certification (CIS).\nExperience working with manufacturing teams in Southeast Asia; Vietnamese language skills a plus.\nProject management training or certification (e.g., PMP) and experience managing capital equipment projects.\nBackground & Knowledge Areas\nIdeal candidates will bring practical understanding in the following areas:\nPower electronics fundamentals - switch-mode power conversion, isolation, creepage/clearance, thermal dissipation, and how component choices affect manufacturability and reliability.\n PCBA manufacturing - paste printing, placement, reflow and wave/selective soldering, and inspection (AOI, AXI); common defect modes and their causes.\nMechanical & final assembly - assembly sequencing, fixture and jig design, torque and fastening methods, thermal interface materials, wire harnessing, and mistake-proofing for high-mix assembly.\nTest strategy - functional/ATE test coverage, safety testing, burn-in/ESS, and fixture design.\nRegulated quality systems - design transfer, change control, traceability, and documentation practices under ISO 13485.\nLean manufacturing - line layout, takt time, standard work, and waste reduction for low-to-medium volume, high-mix production.\nTools & Systems\nERP/MRP and PLM - [e.g., Oracle / SAP; Agile / Arena]\n Mechanical CAD - SolidWorks (required)\n PCB CAD / DFM - Altium Designer (preferred); Valor or equivalent Gerber/CAM tools\nQuality & analysis - PFMEA, control plans, SPC, Minitab\n Office - Microsoft 365 (Excel, PowerPoint, Project or equivalent)\nWork Environment & Physical Requirements\nBased on-site at our US manufacturing facility (no remote work); regular time on the production floor.\nWork around electronic assembly equipment, chemicals (solder, flux), and high-voltage test stations; adherence to ESD and safety procedures required. PPE provided.\nAbility to stand/walk for extended periods and lift up to [25] lbs.\n 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.\nOccasional flexibility to support builds outside standard hours.\n XP 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.\nWe also offer a comprehensive benefits package including:\n100% Employer Paid Medical, Dental and Vision Insurance for full-time Employee-only coverage; you share the cost of coverage for your dependents\nCompany Paid Bonus (Percentage dependent on Company profitability)\nCompany 401(k) Match (up to 6%)\nMental Health Benefits\nPaid Time Off (Accrued per pay period starting at 3 weeks per year)\n13 Company Paid Holidays \nPaid Time Off for Volunteer Work (up to 8 hours per year)\nEmployer Paid Supplemental Short-Term and Long-Term Disability Insurance \nVeterinary Pet Insurance\nCompany Social Events held throughout the year\nA Friendly Culture Where People Collaborate and Strive for Excellence\nAll your information will be kept confidential according to EEO guidelines.","description_format":"text","description_chars":11498,"description_truncated":false,"requirements":{"experience_years_min":6,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":false,"languages":[{"language":"English","level":"All levels","optional":false},{"language":"Vietnamese","level":"All levels","optional":true}]},"benefits":["Vision insurance"],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":["Power Supplies & Power Electronics"],"lifecycle":[{"event":"open","at":"2026-10-22T19:32:34Z"}],"visa":[{"country":"US","licensed_sponsor":true,"evidence":"H-1B filings in 12 months: 5 · green card filings: 1","filings_12m":5,"filings_prev_12m":8,"green_card_filings_12m":1,"median_offered_wage_usd":127500,"route":null,"cap_exempt":false,"checked_at":"2026-10-15T11:24:14+00:00","sources":["US Department of Labor: LCA disclosure data (H-1B, H-1B1, E-3)","US Department of Labor: PERM disclosure data (green cards)"],"filings_for_role_12m":0}],"liveness":{"score":60,"band":"ok","label":"Likely open","p_open":1,"p_active":0.602,"p_room":1,"age_days":2,"expected_fill_days":46,"reasons":["conf:0","stale_co","win:early"],"computed_at":"2026-10-25T05:49:26Z"},"pay":{"stated_usd_annual":140000,"is_top_pay":true},"html_url":"https://alion.io/job/xp-power-manufacturing-npi-engineer","json_url":"https://alion.io/job/xp-power-manufacturing-npi-engineer.json","meta":{"generated_at":"2026-10-25T19:27:31Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":27631,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-10-26T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":8620},"rest":"https://alion.io/mcp/rest/get_company?id=8620"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fxp-power-manufacturing-npi-engineer"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fxp-power-manufacturing-npi-engineer"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fxp-power-manufacturing-npi-engineer"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/xp-power-manufacturing-npi-engineer\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fxp-power-manufacturing-npi-engineer"}]}