Test Manager

 

Test Manager — AOI / AXI Operations

Position Summary

The Test Manager — AOI / AXI Operations is responsible for leading the Automated Optical Inspection and Automated X-ray Inspection departments within a high-reliability PCBA manufacturing environment. This role oversees AOI and AXI operators, line leads, and supervisors to ensure inspection output, product quality, staffing coverage, machine utilization, and compliance with customer and IPC requirements.

This position requires a hands-on manufacturing leader who can drive daily execution, improve inspection performance, reduce defects and escapes, and partner closely with Production, Engineering, Quality, and Maintenance to keep work moving efficiently through the factory.

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Responsibilities

Department Leadership

• Manage daily operations for AOI and AXI inspection areas, including staffing, priorities, shift coverage, and production flow.
• Lead operators, line leaders, and supervisors to ensure work is completed safely, accurately, and on schedule.
• Monitor department performance throughout the day and adjust resources as needed to support production demands.
• Maintain accountability across the team for attendance, productivity, quality, and adherence to process requirements.
• Support a positive, disciplined, and team-focused work environment.

Team Development

• Provide coaching, training, and performance feedback to supervisors, leads, and operators.
• Conduct performance reviews and help identify development opportunities for team members.
• Ensure employees are properly trained on AOI/AXI equipment, inspection requirements, documentation, and escalation processes.
• Build a strong leadership structure within the departments to support multiple shifts and changing production priorities.

Quality and Inspection Performance

• Ensure AOI and AXI inspection processes meet IPC-A-610, customer specifications, and internal quality standards.
• Drive improvements to reduce defects, inspection escapes, false calls, and unnecessary rework.
• Partner with Quality and Engineering on root cause analysis, corrective actions, and preventive actions.
• Review inspection trends and use data to identify recurring issues, process weaknesses, and training needs.
• Ensure inspection results are properly documented and escalated when defects or process concerns are identified.

Production Efficiency and KPI Management

• Track and improve key department metrics, including throughput, output, first pass yield, utilization, downtime, false call rate, and inspection cycle time.
• Coordinate with Production, Planning, Engineering, and Quality to resolve bottlenecks and maintain schedule alignment.
• Balance inspection quality with production efficiency to support customer delivery requirements.
• Identify opportunities to improve workflow, staffing models, machine utilization, and overall department performance.

Process Control and Program Management

• Ensure AOI and AXI machine programs are properly set up, validated, maintained, and optimized.
• Support new product introduction builds, including inspection program validation, first article review, and qualification activities.
• Maintain standard work instructions, process documentation, and inspection procedures.
• Ensure consistent execution of inspection standards across shifts and operators.
• Support continuous improvement projects related to inspection accuracy, cycle time, and process repeatability.

Equipment Support

• Partner with Maintenance and Engineering to maximize AOI and AXI machine uptime.
• Support preventive maintenance schedules, troubleshooting activities, and escalation of equipment issues.
• Ensure operators follow proper equipment care, setup, and usage procedures.
• Help identify equipment, tooling, or software needs required to improve department performance.

Reporting and Communication

• Provide daily and weekly updates on department performance, production status, staffing, quality issues, and equipment concerns.
• Communicate clearly with senior leadership and cross-functional teams regarding risks, delays, and improvement actions.
• Escalate issues quickly when production, quality, or customer delivery may be impacted.
• Maintain accurate records related to inspection results, department metrics, training, and corrective actions.

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Qualifications

Education and Experience

• Associate or bachelor’s degree in Engineering, Electronics, Manufacturing, or a related technical field preferred.
• 3–5+ years of experience in SMT manufacturing, AOI, AXI, test, inspection, or PCBA operations.
• Previous supervisory, lead, or management experience in a manufacturing environment preferred.
• Experience in high-reliability electronics, aerospace, medical, defense, or other regulated manufacturing environments is a plus.

Technical Skills

• Strong understanding of SMT processes and printed circuit board assembly.
• Working knowledge of AOI and AXI inspection systems; experience with equipment such as Omron, Koh Young, or similar platforms preferred.
• Knowledge of IPC-A-610 requirements; Class 3 experience preferred.
• Ability to read and interpret manufacturing documentation, inspection criteria, customer requirements, and quality standards.
• Strong ability to analyze inspection data, identify trends, and drive corrective actions.
• Comfortable using production systems, spreadsheets, reports, and KPI dashboards to manage department performance.

Leadership Skills

• Proven ability to lead teams in a fast-paced manufacturing environment.
• Strong communication, coaching, and organizational skills.
• Ability to manage priorities across multiple shifts, departments, and production demands.
• Strong problem-solving skills with a practical, hands-on approach.
• Ability to hold teams accountable while maintaining a professional and respectful work environment.

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Key Competencies

• Strong leadership and accountability
• Quality-focused decision making
• Data-driven problem solving
• Continuous improvement mindset
• Cross-functional collaboration
• Strong attention to detail
• Ability to manage urgency and changing priorities
• Clear communication with operators, supervisors, peers, and senior leadership

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Working Conditions

• Manufacturing floor environment within SMT/PCBA production.
• Regular interaction with AOI, AXI, SMT, Quality, Engineering, and Production teams.
• May require standing, walking the production floor, and supporting equipment or production issues as needed.
• Flexibility may be required to support multiple shifts, overtime, or urgent production needs.