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