About the role
Senior Industrial Engineer – AI Server RMA (Field Repair) Operation Position Summary This position is responsible for optimizing the end-to-end Return Material Authorization (RMA) and field-repair operation, including product receiving, triage, diagnostics, disassembly, component repair/replacement, liquid-cooling service, system integration, testing, quality verification, packaging, and return-to-customer flow. The Senior Industrial Engineer will use data-driven methods to improve throughput, turnaround time (TAT), labor productivity, capacity, quality, ergonomics, and operational cost while ensuring processes are scalable, safe, traceable, and repeatable.
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Key Responsibilities RMA & Repair Operations * Design, optimize, and maintain end-to-end RMA workflows from receiving and triage through diagnosis, repair, testing, final inspection, and shipment. * Establish standard repair routes for common server and liquid-cooling failure modes. * Identify bottlenecks, queue time, rework loops, excessive handling, and non-value-added activities. * Develop processes capable of handling variable RMA demand, product configurations, and repair complexity. * Support field-repair requirements and translate field service issues into improved factory repair processes.
Industrial Engineering & Capacity * Perform time studies, work measurement, line balancing, capacity modeling, staffing analysis, and workstation optimization. * Establish engineered labor standards and manpower requirements by repair type/product family. * Model capacity for receiving, diagnostics, repair, coolant service, testing, burn-in, packaging, and shipment. * Develop scenarios for demand ramps and changing RMA volumes. * Analyze WIP and queue levels and recommend appropriate capacity buffers. * Drive productivity improvements while maintaining product quality and technician safety. * Optimize service processes involving cold plates, manifolds, hoses, quick-disconnects, pumps/CDU interfaces, coolant handling, leak inspection, flushing/filling, and pressure/leak testing, where applicable. * Work with EHS and engineering teams to ensure safe handling of heavy, high-value server assemblies and cooling systems. * Incorporate appropriate ergonomics and material-handling solutions for racks, trays, servers, and repair fixtures.
Lean Manufacturing & Continuous Improvement * Lead Lean, Kaizen, 5S, Value Stream Mapping, DMAIC, and structured problem-solving activities. * Apply Pareto analysis, 5-Why, Ishikawa/Fishbone, FMEA, SPC, and root-cause analysis to operational problems. * Reduce waste associated with waiting, movement, transportation, inventory, overprocessing, defects, and rework. * Develop standardized work and visual management for critical RMA processes. * Facilitate cross-functional improvement workshops and drive actions through closure.
Factory Layout & Workstation Design * Develop and maintain layouts for repair cells, diagnostic stations, test areas, WIP locations, coolant-service areas, material supermarkets, and finished-goods staging. * Define space, equipment, tooling, utilities, ESD, material-flow, and ergonomic requirements for new or expanding operations. * Optimize factory flow to minimize travel distance and unnecessary product handling. * Support introduction and qualification of new workstations, fixtures, tooling, and automation.
Data, KPI & Digital Operations * Develop dashboards and operating metrics for: * RMA turnaround time * Units repaired per labor hour * Repair/retest rate * WIP and aging * Queue time * Capacity utilization * Labor efficiency * On-time completion * Use production data to identify constraints and prioritize improvements based on operational and financial impact. * Partner with IT/MES teams to improve repair routing, traceability, data collection, defect coding, and electronic work instructions.
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Qualifications Required * Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, Systems Engineering, or a related technical field. * Typically, 5+ years of relevant industrial/manufacturing engineering experience, including ownership of complex production or repair processes. * Demonstrated experience with: * Time studies and labor standards * Capacity and manpower modeling * Line/cell balancing * Factory/workstation layout * Standardized work * Lean manufacturing * Root-cause analysis * Continuous improvement * Strong data-analysis capability using Microsoft Excel and similar analytical/reporting tools. * Experience working cross-functionally with Operations, Manufacturing Engineering, Quality, Test, Materials, Planning, IT/MES, and EHS. * Ability to operate effectively in a fast-paced environment with changing volume, priorities, and technical requirements. * Strong written, verbal, analytical, and technical presentation skills.
Preferred * Experience with server, rack, storage, networking, electronics, semiconductor, or other high-tech manufacturing/repair environments. * Experience supporting RMA, depot repair, field service, failure analysis, or reverse logistics. * Knowledge of AI/HPC server architecture and high-density compute environments. * Experience with MES, ERP, WMS, Power BI, SQL, Minitab, AutoCAD/Factory Design, or simulation tools. * Lean Six Sigma Green Belt or Black Belt certification is desirable. * Familiarity with ISO 9001, ESD controls, PFMEA, Control Plans, and high-tech manufacturing quality systems is preferred.
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Key Competencies * Industrial engineering and operations optimization * Capacity and labor planning * Data-driven problem solving * Lean manufacturing and continuous improvement * Factory and material-flow optimization * High-mix / variable-demand operations * Cross-functional leadership