Foxconn Industrial Internet - FII
Senior Industrial Engineer–AI Server RMA (Field Repair) Operation
Houston, TX - Full Time
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
Qualifications
Required
Key Competencies
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.
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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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
