Debug Test Technician

Job Description

Position Summary

The Debug Test Technician troubleshoots and repairs power supply assemblies to component level, keeping units that fail test moving back into production. Working across volume production, new product introduction (NPI) builds, and customer returns (RMA), you will be the bridge between the test floor and engineering whenever boards don't pass.

In this role you will diagnose failures in power conversion circuits, perform rework to IPC workmanship standards, capture failure data that drives yield and quality improvements, and help keep functional test stations running. This is a hands-on, on-site role on the production floor and in the debug lab, working closely with Test Engineering, Manufacturing Engineering, Design Engineering, Quality, and Production.

Key Responsibilities

Production Debug & Repair

• Debug and repair failed power supply from top level assembly(TLA) down to PCBA/component level using schematics, BOMs, and assembly drawings.
• Diagnose failures in PFC stages, primary-side switching, magnetics, isolated feedback loops, secondary-side regulation, and protection circuits.
• Turn around boards that fail in-circuit or functional test to keep WIP moving and first-pass yield up.
• Verify repaired units through retest and confirm they meet specification before returning them to the line.

NPI & Pilot Build Support

• Debug failures on NPI and pilot builds, and help engineering separate design, process, and component issues.
• Provide hands-on feedback on debug access, test points, and repairability during early builds.

RMA / Customer Returns

• Reproduce reported failures on customer returns, identify root cause, and repair or disposition units.
• Document RMA findings clearly so Quality and Engineering can respond to customers and drive corrective action.

Rework & Workmanship

• Perform SMT and through-hole soldering and rework, including fine-pitch components, using hot air and rework stations.
• Work to IPC-A-610 workmanship standards and follow ESD-safe handling at all times.

Failure Data & Reporting

• Log every failure, root cause, and repair action in the failure database/MES with serial-level traceability.
• Build failure Pareto and trend reports, and flag emerging issues early.
• Provide data and analysis for 8D and corrective action (CAPA) investigations.

Engineering Collaboration

• Work with Test, Design, and Manufacturing Engineering on recurring defects; suggest DFM/DFT improvements.
• Communicate debug status, findings, and risks clearly to engineering and production leads.

Test Fixture & Station Support

• Maintain and troubleshoot functional test fixtures and stations, including AC sources, electronic loads, wiring, and interfaces.
• Support fixture upkeep such as pogo pin replacement and connector wear, and escalate tester issues to Test Engineering.

Qualifications

Required Qualifications

• 2–5 years of hands-on TLA & PCBA debug experience in electronics manufacturing, ideally on switch-mode power supplies.
• Solid understanding of analog and power electronics: rectification, PFC, flyback/forward/resonant topologies, feedback loops, and protection circuits.
• Ability to read and work from schematics, BOMs, and assembly drawings; strong troubleshooting skills to component level.
• Proficiency with oscilloscopes (including differential and current probes) and digital multimeters.
• Experience with programmable AC sources, electronic loads, and power analyzers.
• Skilled SMT and through-hole soldering and rework, including fine-pitch parts.
• Safe working habits around high voltage and ESD-sensitive assemblies.
• Clear written documentation of failures and repairs; comfortable with Excel and MES or failure-tracking systems.
• Ability to prioritize across production, NPI, and RMA work.

Preferred Qualifications

• Associate's degree in Electronics Technology or similar — or equivalent military/vocational training and hands-on experience.
• Current IPC-A-610 and/or J-STD-001 certification.
• Experience supporting NPI builds or RMA/failure analysis in a contract or OEM manufacturing environment.
• Familiarity with 8D, 5-Why, and corrective action processes.
• Experience maintaining functional test fixtures or automated test stations.
• Experience in an ISO 9001 or ISO 13485 (medical) regulated environment.

Background & Knowledge Areas

Ideal candidates will bring practical understanding in the following areas:

• Power electronics fundamentals — switch-mode conversion, isolation, protection circuits, and how these show up as failure modes.
• Debug methodology — systematic fault isolation, signal tracing, and component-level verification on energized and de-energized boards.
• Workmanship — IPC-A-610 acceptance criteria, rework techniques, and common solder and assembly defects.
• Safety — high-voltage and ESD practices for working on energized power assemblies.

Tools & Equipment

• Measurement — oscilloscopes, differential and current probes, DMMs
• Power test — programmable AC sources, electronic loads, power analyzers
• Rework — soldering and hot-air rework stations, microscopes
• Systems — MES / failure-tracking database, Microsoft 365 (Excel)

Work Environment & Physical Requirements

• Based on-site at our US manufacturing facility (no remote work), day shift; time split between the debug lab and the production floor.
• Work around energized high-voltage assemblies, test stations, and chemicals (solder, flux); adherence to ESD, high-voltage, and safety procedures required. PPE provided.
• Ability to sit or stand at a bench for extended periods, perform fine-pitch work under magnification, and lift up to [25] lbs.
• Occasional flexibility to support builds and production issues outside standard hours.

Additional Information

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. 

We also offer a comprehensive benefits package including:

• 100% Employer Paid Medical, Dental and Vision Insurance for full-time Employee-only coverage; you share the cost of coverage for your dependents
• Company Paid Bonus (Percentage dependent on Company profitability)
• Company 401(k) Match (up to 6%)
• Mental Health Benefits
• Paid Time Off (Accrued per pay period starting at 3 weeks per year)
• 13 Company Paid Holidays 
• Paid Time Off for Volunteer Work (up to 8 hours per year)
• Employer Paid Supplemental Short-Term and Long-Term Disability Insurance 
• Veterinary Pet Insurance
• Company Social Events held throughout the year
• A Friendly Culture Where People Collaborate and Strive for Excellence

All your information will be kept confidential according to EEO guidelines.

Compensation: 27 to 33 (USD) (HOURLY)