Test System Design Engineer

The Test System Design Engineer will be responsible for the design, development, and implementation of test systems to ensure the quality and reliability of our products. This role involves working closely with product and engineering teams to understand test requirements, develop detailed test plans, and create custom Automated Test Equipment (ATE) systems. The successful candidate will have a strong well-rounded background in control systems, test engineering tools, quality control, and the ability to manage multiple concurrent projects.

Key Responsibilities

• Requirement Analysis : Collaborate closely with product teams to understand and define test requirements, including performance metrics, environmental conditions, market demands, and regulatory agency compliance standards (UL,EU,AGA)

• Test Planning: Develop detailed test plans, including test cases, test scripts, and validation protocols, to ensure comprehensive coverage of product functionalities and performance. Utilize quality management tools – DFMEA, PFMEA, and Systems thinking to plan effective and efficient test plans to maximize quality with supporting necessary production capacity and throughput

• Design and Development: Design and develop custom test systems and equipment tailored to the specific needs of a wide range of OEM commercial appliance products. This includes selecting, purchasing, and hands-on creating mechanical, electrical, and software components of production capable test systems.

• Mechanical Design: Create CAD models for test fixtures and equipment. Select appropriate sensors, actuators, and control systems hardware to achieve accurate and reliable testing

• Electrical Design: Design electrical system interface from Unit Under Test (UUT) and Data Acquisition and Measurement test equipment. Document system components and interconnect schematics with ECAD tools for ATE design, assembly, and maintenance.

• Software Development: Develop and or oversee the development of test software, including data acquisition, control algorithms, and user interfaces. Ensure seamless integration with test hardware.

• Prototyping and Validation: Build and validate prototypes of test systems. Conduct initial testing to identify any design flaws and make necessary adjustments.

• Own Test Equipment Lifecycle Implementation: Oversee the implementation of test systems in production environments. Ensure proper calibration, configuration, and integration with existing manufacturing processes. Meet product production schedule and NPI timing.

• Troubleshooting and Support: Provide ongoing support for test systems, including troubleshooting hardware and software issues, maintaining appropriate level of tester backup components, performing regular maintenance, and implementing updates or improvements to reduce downtime.

• Documentation: Develop and maintain comprehensive documentation for test systems, including design specifications, user manuals, maintenance procedures, and test reports required to train, repair, or reproduce.

• Test Engineering SME: Train production and engineering teams on the use and maintenance of test systems. Provide guidance and support to ensure effective and efficient testing processes. Participate in Design for Test / Design for Assembly activities that improve test effectiveness and performance.

• Continuous Learning: Stay current with industry trends and advancements in test system technologies. Identify opportunities for process improvements and implement best practices to enhance test accuracy and efficiency. Champion continuous improvement of Test Engineering processes.

• Project Management: Manage multiple internal and external test system development projects simultaneously as needed. Coordinate with cross-functional teams to ensure projects are completed on time and within budget.

Qualifications:

• Bachelor’s degree in Electrical / Computer Engineering, Mechanical Engineering, or a related field.
• 3-5 years of experience in designing and developing test systems for manufacturing environments.
• Strong understanding of test methodologies and equipment.
• Proficiency in using one or more design and simulation software applications to meet Key Responsibilities (e.g., SolidWorks, AutoCAD, Altium, KiCAD, LabVIEW, MATLAB/Simulink).
• Experience with automated data acquisition, test instrumentation, and control system use and integration.
• Strong problem-solving skills and the ability to troubleshoot complex systems.
• Excellent communication and teamwork skills.
• Ability to work independently and manage multiple projects simultaneously.
• Knowledge of industry standards and regulations related to test systems and product quality.
• Experience with automated and semi-automated test systems.
• Experience with microcontrollers, sensors, interfacing and programming, i.e., Arduino, Raspberry Pi.
• Familiarity with PLC programming and HMI design.
• Knowledge of statistical process control (SPC) and other quality control methods.
• Strong project management skills.
• Certification in relevant fields (e.g., Certified Test Engineer, Six Sigma).