DMF & DFSS Engineering Leader- Hybrid

About us:

LayerZero Power Systems, Inc. is a leader in power management products for mission and process critical applications. Our customer base is comprised of companies in the computer service provider (on-line commerce, streaming, hosting, etc.), semiconductor manufacturing and financial sectors. LayerZero provides innovative products to ensure user safety and ultimate reliability of computers, servers, communication gear, and other critical equipment. LayerZero manufactures best-in-class products representing high-end solutions. LayerZero Power Systems is on a trajectory of sustained growth, with a loyal base of existing Fortune 100 customers and an expanding portfolio of new customers.

Position Summary

Support Design for Manufacturing (DFM) and Design for Startup and Service (DFSS) across all LayerZero products and integrated solutions, with a strong focus on solid-state power conversion and switching.

Scope includes STS, PDU/Mega PDU, RPP, AC/DC systems, controls and monitoring. Deliver assigned improvements that make products easier to build, safely energize, diagnose and maintain.

Key Responsibilities

•Execute assigned DFM/DFSS work packages. Prepare readiness evidence, track actions and escalate risks to Program leadership and technical owners. 

•Work with key partners, National Labs, standards groups, and other suppliers/partners to translate solid-state technology into DFM/DFSS requirements, pilot builds and validated startup/service procedures.

 •Review assembly and wiring with Manufacturing and suppliers. Recommend improvements to access, tolerances, tooling and error-proofing. 

•Support power-electronics engineers on SiC/GaN, MOSFET and IGBT assemblies, including thermal interfaces, busbars, insulation and replaceable modules.

 •Help develop factory test access, fixtures, calibration instructions and traceability for power stages, sensing and protection functions. 

•Draft startup methods of procedure and energization checklists for approval by qualified commissioning and safety teams. •Check designs against approved isolation, stored-energy discharge, interlock and fault-recovery requirements with technical specialists. •Document service access, module replacement and spares. Maintain troubleshooting guides, diagnostic records and configuration instructions. 

•Participate in design/process FMEA and factory, site and integrated systems testing. Record findings and follow assigned corrective actions. 

•Support root-cause investigations. Collect factory and field evidence and prepare controlled change requests for engineering review. 

•Support pilot builds and field validation with Engineering, Quality, Operations and Service. Prepare training and handoff records. •Maintain first-pass yield, rework, startup and repair-time data. Report trends and progress against agreed improvement targets.  

Requirements

Qualifications

•Technical degree or equivalent relevant experience. 

•10+ years in industrial electrical systems or field engineering. 

•Hands-on startup, QA/Cx, electrical safety and root-cause failure analysis experience. 

•Translate drawings and field issues into build/service requirements. 

•Work effectively with suppliers, trades and customer engineering. 

Preferred

•Solid-state integration and manufacturing/test or service engineering. 

•Critical-power equipment, MV/LV switchgear, UPS, generators and AC/DC systems. 

•FMEA, drawing release/change control and NFPA, UL/IEC familiarity. 

External Engagement

•Support IEEE, NEMA, NFPA and IEC working groups with Compliance. Bring applicable standards, OSHA requirements and EPRI research into DFM/DFSS reviews and test plans. 

Role Boundaries

•Individual contributor reporting to Engineering Programs Director, retains design authority. Operations, Service and Compliance retain functional approvals.  

Ideal candidate will travel up to 40% between: Raleigh, NC to Knoxville, TN and Aurora, OH

What We Offer:

• Competitive pay with performance incentives
• 100% company-paid medical, dental, and vision
• 401(k) with company match
• 4 weeks PTO, 10 paid holidays, and 2 floating holidays

Why You Will Love Working with Us:

• Impact: Develop your skills and expertise in a rapidly growing industry, with your work directly influencing the success of mission-critical projects.
• Innovation: Immerse yourself in an environment that celebrates forward-thinking and continuous improvement.
• Collaborative spirit: Work closely with engineers, marketers, and other professionals to bring ideas to life.
• Grow with us: We are committed to your personal and professional development, offering endless opportunities to improve your skills and advance your career

At LayerZero, we are proud to be an Equal Opportunity Employer. We welcome and celebrate diversity, and we are committed to creating an inclusive environment for all employees.