Senior Industrial Engineer–AI Server RMA (Field Repair) Operation

Houston, TX
Full Time
Experienced
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.
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.


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.
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
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