Failure Analysis/Reliability Engineer

We are seeking a collaborative, detail‑oriented, and safety‑focused failure analysis and reliability engineer to support root cause investigations, reliability improvement initiatives, and assurance of product and equipment performance across laboratory, pilot‑plant, and light industrial environments. The successful candidate will partner with R&D, process engineering, manufacturing, quality, and EHS teams to identify failure mechanisms, recommend corrective and preventive actions, and drive data‑driven reliability strategies. This role requires strong analytical judgment, clear cross‑team communication, hands‑on failure characterization, and a commitment to safety, quality, and continuous improvement.

Key Responsibilities

• Lead failure investigations for components, assemblies, and systems by collecting evidence, preserving failure artifacts, and executing systematic root cause analysis (e.g., 5‑Why, Fishbone, Fault Tree, FMEA).

• Perform physical and non‑destructive examinations including visual inspection, microscopy, hardness testing, metallography, and NDT methods; coordinate laboratory testing such as chemical analysis, SEM/EDS, X‑ray, and mechanical testing.

• Develop and execute test plans to reproduce failures, validate failure hypotheses, and assess corrective actions; design controlled experiments and accelerated life tests to quantify failure rates and modes.

• Analyze field and test data using statistical techniques and reliability tools (Weibull, MTBF/MTTR analysis, life data analysis, reliability growth modeling) to identify trends and prioritize improvements.

• Collaborate with design, process, and manufacturing teams to translate failure findings into durable design changes, material selections, process controls, and assembly/inspection improvements that reduce risk and improve maintainability.

• Prepare concise, well‑documented technical reports that summarize investigation scope, evidence, analysis, conclusions, and recommended corrective and preventive actions (CAPA); present findings to stakeholders and leadership.

• Support supplier quality activities by reviewing vendor test data, performing supplier audits or technical assessments, and defining incoming inspection criteria to mitigate recurring failures.

• Contribute to reliability engineering activities including development of reliability test programs, maintenance strategies, condition monitoring plans, and spare parts recommendations.

• Maintain accurate evidence handling, chain‑of‑custody records, and technical documentation with appropriate revision control and traceability to support regulatory or quality investigations.

• Participate in safety and incident investigations related to equipment or product failures; ensure corrective actions address safety and compliance concerns and follow through to closure.

• Mentor junior engineers and technicians in failure analysis methods, test procedures, and reliability best practices; contribute to the development and maintenance of investigation templates, checklists, and training materials.

Required Qualifications - Skills & Experience

• Bachelor’s degree in Mechanical Engineering, Materials Science, Reliability Engineering, or a closely related discipline, or equivalent professional experience.

• 3+ years of practical experience in failure analysis, reliability engineering, or related investigative roles in industrial, laboratory, or manufacturing environments.

• Hands‑on experience with failure characterization techniques (metallography, microscopy, SEM/EDS, hardness, fractography) and familiarity with non‑destructive testing methods.

• Working knowledge of reliability analysis methods (Weibull analysis, life data analysis, MTBF/MTTR, FMEA) and comfort applying statistical methods to analyze failure data and support decision‑making.

• Experience performing root cause analysis (RCA) and driving CAPA with cross‑functional teams; ability to document investigations clearly and track closure of actions.

• Strong technical writing and communication skills: able to prepare concise technical reports, present investigation outcomes to cross‑functional stakeholders, and coordinate with vendors and suppliers.

• Proficiency with data analysis tools (e.g., Excel, Minitab, R, Python) and experience with reliability or lab data management systems preferred.

• Attention to detail, excellent problem‑solving skills, and the ability to manage multiple priorities in a dynamic work environment.

• Commitment to safety, quality, and regulatory compliance; awareness of laboratory safety practices, evidence handling, and mechanical hazard mitigation.

Preferred Qualifications - Domain & Tools

• Master’s degree in Materials Science, Reliability Engineering, Mechanical Engineering, or related field for roles with increased technical responsibility.

• Professional certifications such as Certified Reliability Engineer (CRE), Six Sigma, or relevant NDT certifications are advantageous.

• Familiarity with material failure mechanisms (fatigue, corrosion, creep, wear), fracture mechanics principles, and relevant industry standards for components and assemblies.

• Experience with SEM/EDS, X‑ray, CT scanning, and laboratory equipment; proficiency with data analysis and visualization tools (Minitab, JMP, Python libraries) beneficial.

• Experience supporting supplier quality and incoming inspection processes, and familiarity with quality systems such as ISO 9001 or AS9100 preferred.

• Training or certifications related to root cause analysis, risk assessment, vibration analysis, or reliability‑centered maintenance are advantageous.

Work Environment & Compensation

• Full‑time position within an interdisciplinary engineering, manufacturing, and EHS organization; work includes office‑based analysis, laboratory testing, hands‑on evidence handling, and periodic presence in pilot‑plant environments.

• Competitive salary and benefits package commensurate with experience, including health coverage, retirement plan options, paid time off, and professional development support.

• Opportunities for training, certifications, conference participation, and career growth within a diverse, inclusive, and safety‑focused workplace.

• We are committed to diversity, equity, and inclusion and foster a respectful work environment that supports work‑life balance and employee well‑being.