System Validation & Automation Engineer III (Senior)

Generac Power Systems, Inc.; Maharashtra; On-site; INR 1,200,000 - 2,200,000; Full time

Job summary

Generac Power Systems, Inc. in Maharashtra seeks a senior hardware design and test engineer to drive design verification, reliability testing, and production test development for consumer electronics products.

You will lead HALT/ALT testing, build test instrumentation, and collaborate across design, manufacturing and quality teams. The role requires 5+ years in electrical hardware development, expertise in PCB design, validation, and debugging, and hands-on experience with lab equipment such as

Qualifications

• Bachelor of Engineering degree in Electronics.
• 5+ years of experience in electrical hardware product development with consumer electronics.
• Involved with full product development and high-volume production—from concept to manufacturing and test.
• Experience in hardware design, validation and test execution.
• Proficiency in schematic design and PCB review; pcb layout fundamentals.
• Hardware debugging and root-cause analysis; analog and high-speed digital analysis.
• Familiarity with lab equipment (oscilloscope, DAQ, DMM, thermal chamber, spectrum analyzer, VNA).
• Soldering/rework of SMT components including 0201, XDFN, TSOT; PCBA manufacturing processes familiarity.
• Understanding of product design principles, thermal management, and embedded systems optimization.
• Strong knowledge of critical parts manufacturers and supply chain considerations.
• Bonus: embedded Linux, C++ for MCU, IoT sensor design, CPU/memory architectures; P.Eng designation.

Responsibilities

• Create and execute engineering verification test plans.
• Prepare and execute reliability tests to support warranty and life targets.
• Conduct HALT/ALT tests to expose design weaknesses.
• Assess test activities against real-world field use.
• Design and build test instrumentation and data capture systems.
• Perform GD&T analyses, yield reports, and testing issue resolution.
• Assist with root-cause analysis of factory issues to improve designs.
• Develop cost-benefit analyses for test coverage and risk.
• Document tests and report results for approvals/rejections.
• Identify and evaluate component substitutes to reduce BOM cost or mitigate supply chain risks.
• Perform environmental, ESD, surge, EFT and compliance testing per UL/IEC/CSA specs.
• Prototype new circuits and create production test plans and fixtures.
• Collaborate to improve all test/verification activities across teams.

Skills

Electrical hardware development

Schematic design

PCB layout fundamentals

Hardware debugging

Embedded systems

Full product development lifecycle

High-speed digital analysis

Analog circuit analysis

Knowledge of PCBA manufacturing

Embedded Linux

C++ development for MCU

CPU architectures (8/16/32/64-bit)

Memory architectures (eMMC, DDR3/4)

PCB layout optimization

IoT sensor design

P.Eng designation

Education

Bachelor of Engineering in Electronics

Tools

Oscilloscope

DAQ

DMM

Thermal chamber

Spectrum analyzer

VNA

Job description

We are Generac, a leading energy technology company committed to powering a smarter world.

Over the 60 plus years of Generac's history, we've been dedicated to energy innovation. From creating the home standby generator market category, to our current evolution into an energy technology solutions company, we continue to push new boundaries.

How You’ll Make an Impact:

• Creating and executing engineering design verification test plans
• Preparing and executing reliability test plans to increase confidence in warranty and service life targets
• Conducting Highly Accelerated Life Tests (HALT) and Accelerated Life Tests (ALT) to expose device vulnerabilities and improve designs
• Perform engineering assessments of test and verification activities against real-world field applications
• Designing and building test instrumentation systems to standardize and automate experiments and data capture of many concurrent DUT simultaneously
• Conducting and reviewing Gage repeatability and reproducibility analyses as well as yield reports and production test issue resolution
• Assist with root causing factory issues with a background of manufacturing processes and design knowledge to isolate variables and find system or component level issues
• PFMEA's and performing assessments and trade-offs of test coverage to conceptualize production test suites for high volume mass production test
• Executing on cost-benefit analyses and risk assessments to optimize production test decisions and coverage
• Documentation and report creation of tests completed
• Analyzing experimentation results and engineering reports from others to issue approval or rejection
• Identifying component alternates and creating test plans to validate substitutions to reduce BOM cost or mitigate supply chain issues
• Environmental, ESD, Surge, EFT and compliance testing of new and existing products
• Researching, identifying and executing on applicable UL, CSA, IEC or other specifications relevant to product development
• Prototyping of new circuits before inclusion into production programs
• Creating of Production Test Plans, Test scripts and Production Test Fixtures
• Collaborating with teammates to improve and guide all test/verification activities (reports, methods, procedures, designs, fixtures) and creating proposals of ideas
• Providing recommendations on design integrity and issuing recommendation to proceed to mass production
• Identify and elevate major design risk factors; identify, validate and propose alternate suggestions with concern for cross-functional impact (feature set, cost targets, design scope, etc.)
• Designing Printed Circuit Boards intended to prototype new circuits, create fixtures, development tools or other uses

What You’ll Bring to the Table:

• Bachelor of Engineering degree in Electronics (or similar)
• 5+ years industry experience in electrical hardware product development with emphasis on consumer electronics
• Must have been involved with full product development and high volume production
  • design concept, circuit design, multiple stages of prototype development and test, entry into manufacturing, test fixtures
  • identify and resolve design issues resulting in more reliable product and easing production
  • identify and resolve field failures and work back improvements into the design.
• Experience in Hardware design, validation and test execution
• Proven experience in Schematic design and review, Printed Circuit Board review
• Printed Circuit Board review and knowledge of PCB layout fundamentals
• Hardware debugging and root cause analysis
• Analog and high-speed digital circuit analysis
• Familiarity with oscilloscope, DAQ, DMM, thermal chamber, spectrum analyzer, VNA among other lab equipment
• Understanding of testing principles and impact on results
• Solder and rework fine pitch electronic SMT components including 0201, XDFN, TSOT
• Familiarity with PCBA manufacturing processes
• Understanding of full product design principles, thermal transfer, etc. and impact on electronics
• Knowledge of embedded systems, architecture, operating states, and optimizations
• Strong industry awareness of critical parts manufacturers

Bonus Points if You Can Bring this to the Table:

• Background in PCB layout including optimization of power distribution networks, stack-up design, high-speed interfaces and high voltage systems
• Experience in low power, IoT sensor design
• CPU architectures, 8 bit, 32 bit and 64 bit experience
• Memory architectures, eMMC, DDR3, DDR4 etc.
• Embedded Linux and C++ development, Ability to write C++ for MCU applications
• Professional Engineer (P.Eng.) designation