# Reliability & Failure Analysis Engineer

**Company:** [Sesame](https://hotfix.jobs/companies/sesame)
**Location:** San Francisco, CA, Bellevue, WA
**Role:** Hardware Engineering
**Salary:** $175k – $280k/yr
**Experience:** 7+ years
**Skills:** Reliability Testing, Failure Analysis, Halt, Alt, Root Cause Analysis, Design For Reliability, Sem, X-Ray, Weibull Analysis, Jmp, Minitab, Consumer Electronics
**Posted:** 2026-07-02

> Reliability & Failure Analysis Engineer responsible for defining/executing test plans (HALT/ALT), performing deep failure analysis on consumer electronics, driving root cause and corrective actions, and influencing DFR in early product development. Requires 7+ years in reliability/FA for consumer electronics plus hands-on experience with FA tools like SEM and X-ray.

## Job Description

## Responsibilities
- Define and execute reliability test plans, including Highly Accelerated Life Testing (HALT), Accelerated Life Testing (ALT), and environmental stress testing.
- Conduct comprehensive failure analysis (FA) on failed units from development, production, and field returns, using advanced analytical techniques and equipment.
- Drive root cause analysis (RCA) and collaborate with cross-functional engineering teams (Mechanical, Electrical, Firmware) to implement effective corrective and preventive actions (CAPA).
- Influence product architecture and design by implementing Design for Reliability (DFR) principles during early development phases.
- Manage reliability lab operations, including equipment maintenance, calibration, and safety protocols.
- Partner with internal and external teams to standardize reliability testing methodologies and validation criteria.
- Support product lifecycle management, from early prototype evaluation through mass production and beyond.
- Develop and maintain technical reports, reliability dashboards, and documentation on product performance trends.

## Requirements
- Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Materials Science, or a related technical field.
- 7+ years of relevant experience in reliability engineering or failure analysis within the consumer electronics industry.
- Hands-on experience with failure analysis tools and techniques, such as X-ray, cross-sectioning, SEM, or optical microscopy.
- Deep understanding of industry-standard reliability testing methodologies and environmental standards.
- Strong problem-solving, communication, and interpersonal skills, with the ability to articulate complex technical findings to diverse teams.

## Nice-to-Haves
- 10+ years of experience in consumer electronics, with a focus on reliability and failure analysis.
- Master’s degree or PhD in Engineering or a related field.
- Proven experience with wearable devices or small form factor, high-density products.
- Experience with statistical analysis software (e.g., JMP, Minitab) and data-driven reliability modeling (e.g., Weibull analysis).
- Demonstrated success in influencing design decisions to improve product robustness and yield.

## Compensation / Benefits
- Salary: $175000 - $280000
- 401(k) with 3.5% employer match
- 100% employer-paid health, vision, and dental benefits
- Unlimited PTO and sick time
- Flexible spending account with employer matching up to $1,650/year
- Employee Assistance Program (EAP)
- Competitive stock options

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