Senior PCBA Sustaining Engineer for AI Hardware

OpenAI; San Francisco (CA); On-site; USD 209,000 - 365,000; Full time

Job summary

OpenAI seeks a PCBA Manufacturing Engineer (Sustaining) to support production and continuous improvement of PCBA platforms in our Industrial Compute hardware. You will work with Hardware Design, Quality, Manufacturing, and Contract Manufacturers to resolve issues and improve yield in high-volume environments.

The role focuses on sustaining engineering after launch, implementing ECOs, and driving CAPA across suppliers and internal teams.

Qualifications

• Bachelor's degree in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, or related field.
• 5+ years supporting high-volume PCBA manufacturing.
• Experience with SMT manufacturing, PCB fabrication, and electronic assembly processes.
• Strong understanding of process control, yield improvement, and statistical analysis.
• Experience with root-cause methods (8D, 5 Why, Fishbone, FMEA).
• Experience working with contract manufacturers and global supply chains.
• Ability to interpret schematics, BOMs, and manufacturing docs.
• Excellent cross-functional communication and project management.

Responsibilities

• Own sustaining manufacturing engineering for PCBA production across multiple hardware platforms.
• Drive root cause investigations for defects, field failures, and escapes.
• Partner with Hardware Design to improve manufacturability (DFM/ DFA/ DFT).
• Support ECOs and manufacturing change implementation.
• Collaborate with contract manufacturers to improve yield, cycle time, and quality.
• Analyze manufacturing data to identify recurring issues and opportunities.
• Develop CAPA for manufacturing and supplier quality issues.
• Support failure analysis across electrical, functional, and process domains.
• Improve documentation, work instructions, assembly processes, and test procedures.
• Collaborate with Test Engineering to enhance production test coverage.
• Support supplier qualification, process validation, and manufacturing readiness for design revisions.
• Travel to manufacturing partners as needed.

Skills

PCBA manufacturing

Sustaining engineering

DFM/ DFA/ DFT

Root cause analysis

CAPA

Contract manufacturers

Manufacturing data analysis

Education

Bachelor's degree in Electrical/Mechanical/Manufacturing Engineering

Tools

MES systems

PLM systems

IPC standards

Job description

OpenAI seeks a PCBA Manufacturing Engineer (Sustaining) to support production and continuous improvement of PCBA platforms in our Industrial Compute hardware. You will work with Hardware Design, Quality, Manufacturing, and Contract Manufacturers to resolve issues and improve yield in high-volume environments.

The role focuses on sustaining engineering after launch, implementing ECOs, and driving CAPA across suppliers and internal teams.