Sr. Engineer - Test Engineering

Senior Engineer – Test Engineering (NPI and Production)

Organization: Cyient DLM Limited

Location: Shamshabad, Hyderabad

Experience: 5-6 Years

Industry: Electronics Manufacturing Services (EMS) / Electronics Manufacturing

Job Summary

We are seeking an experienced Test Engineer with strong expertise in PCBA testing, debugging, and manufacturing test engineering. The ideal candidate should have hands-on experience in production environments, NPI support, test development, failure analysis, and quality methodologies within an EMS setup. The role involves working closely with customers, suppliers, manufacturing, quality, and engineering teams to ensure product reliability, process efficiency, and production excellence.

Key Responsibilities

Test Engineering & Product Validation

• Perform PCBA troubleshooting, debugging, and root cause analysis.
  
• Define test strategies, test specifications, validation plans, and test reports.
  
• Support New Product Introduction (NPI) activities and product qualification.
  
• Develop and execute manufacturing test procedures and validation activities.
  
• Conduct manual, bench-level, cold, and functional testing of electronic assemblies.
  

Production Support

• Support production testing activities to achieve daily output and quality targets.
  
• Monitor yield trends, identify failure patterns, and implement corrective actions.
  
• Perform line balancing and optimize test processes to improve productivity.
  
• Ensure maximum tester uptime through preventive maintenance and calibration activities.
  
• Drive continuous improvement initiatives for test efficiency and cost reduction.
  

Test Development & Equipment Management

• Develop, validate, and support ICT (In-Circuit Test) and FCT (Functional Test) solutions.
  
• Manage tester installation, commissioning, validation, calibration, and preventive maintenance.
  
• Coordinate fixture development, qualification, and troubleshooting activities.
  
• Review product designs and provide Design for Testability (DFT) recommendations.
  
• Ensure effective management of 4M (Man, Machine, Material, and Method) requirements.
  

Customer & Supplier Coordination

• Collaborate with customers during technical discussions, issue resolution, and project execution.
  
• Work with suppliers and cross-functional teams to resolve test-related challenges.
  
• Support engineering changes, process implementation, and validation activities.
  

Documentation & Process Control

• Prepare and maintain test specifications, SOPs, work instructions, checklists, and validation documents.
  
• Develop and maintain Process Flow Diagrams (PFD), Device History Records (DHR), and related manufacturing documentation.
  
• Support project planning through effort estimation, timelines, SRS, and WBS preparation.
  
• Ensure compliance with internal quality standards and customer requirements.
  

Quality & Continuous Improvement

• Apply quality tools such as:
  
  • PFMEA
    
  • Control Plan
    
  • GRR & MSA
    
  • Cp/Cpk Analysis
    
  • IQ/OQ/PQ Validation
    
  • Quality Improvement Plans (QIP)
    
• Drive corrective and preventive actions based on data-driven analysis.
  
• Lead root cause investigations and implement sustainable solutions.
  

Required Skills & Qualifications

• Bachelor's Degree in Electronics, Electrical, Instrumentation, or related discipline.
  
• 5-6 years of experience in EMS/PCBA manufacturing environments.
  
• Strong knowledge of PCBA debugging and electronics testing methodologies.
  
• Hands-on experience with ICT, FCT, and production test systems.
  
• Experience in failure analysis, yield improvement, and process optimization.
  
• Good understanding of DFT principles and manufacturing quality tools.
  
• Strong analytical, problem-solving, and troubleshooting skills.
  
• Excellent communication and stakeholder management abilities.
  
• Ability to work effectively with cross-functional teams, customers, and suppliers.
  

Preferred Skills

• Experience in high-volume electronics manufacturing.
  
• Knowledge of Lean Manufacturing and Continuous Improvement methodologies.
  
• Exposure to Medical Devices, Automotive, Industrial Electronics, or Consumer Electronics products.
  
• Familiarity with statistical process control and manufacturing KPI monitoring.