Senior Failure Analysis & Sustainment Engineer
Leads failure analysis, root cause investigations, and sustainment for fielded autonomous systems hardware. Drives reliability improvements, obsolescence mitigation, and cross-functional collaboration with hands-on troubleshooting of mechanical/electromechanical components. Requires 5+ years experience and bachelor's in engineering.
What You'll Do
Own and build failure analysis processes
- Establish, implement, and continuously improve processes for identifying, documenting, and quantifying failure modes
- Lead and manage FRACAS data workflows and ensure high-quality reliability data capture
- Translate failure data into actionable product and process improvements that enhance system uptime
Lead investigations and root cause analysis (RCA)
- Drive discrepancy report investigations from intake through resolution
- Perform hands-on forensic analysis of failed components and systems
- Determine root cause using structured methodologies (e.g., 5 Whys, fishbone, fault tree)
- Serve as technical authority for product failures
- Act as SME supporting refurbishment and inspection technicians
- Provide engineering guidance for troubleshooting, repair decisions, and escalation
- Interface with design, manufacturing, and reliability teams to close the loop on issues impacting mission-critical systems
Cross-functional collaboration
- Work closely with product design, manufacturing, sustainment logistics, program teams, customer success, and reliability engineering
- Communicate findings clearly to both technical and non-technical stakeholders
Drive reliability and sustainment initiatives
- Identify trends and systemic issues across fielded systems
- Lead initiatives to improve product durability, maintainability, and lifecycle performance for mission-critical applications
Support engineering changes and obsolescence management
- Source, test, qualify, and implement replacement parts
- Contribute to design updates driven by reliability, availability, and maintainability (RAM) objectives
Enable predictive maintenance capabilities
- Analyze correlations between hardware failures and internal system data
- Develop frameworks for predictive failure modeling and condition-based maintenance to improve uptime
Minimum Qualifications
- Bachelor’s degree in Mechanical Engineering or related field (advanced degree a plus)
- 5+ years of experience in mechanical systems engineering, failure analysis, or reliability engineering
- Hands-on experience troubleshooting mechanical and electromechanical systems
- Strong root cause analysis skills and familiarity with structured problem-solving methods
- Experience working cross-functionally in product development or operations environments
Preferred Qualifications
- Experience with FRACAS systems and reliability data analysis
- Background in forensic engineering or failure investigation
- Familiarity with autonomous systems, robotics, or complex electromechanical products
- Experience with test design, validation, and qualification processes
- Working knowledge of electrical systems and diagnostics
US Salary Range
$140,000 - $185,000
Spacecraft Systems Engineer
Design, develop, and test spacecraft systems and subsystems across the full satellite lifecycle. Lead requirements derivation, subsystem budgeting, verification planning, and technical milestones while collaborating with multi-disciplinary teams.
Senior Manufacturing Process Engineer
Develop and optimize pre- and post-processing manufacturing technologies for Carbon's DLS platform. Drive process solutions, design fixtures/tooling, and support production of complex electromechanical assemblies in a fast-paced environment.
Hardware Operations Manager
Lead hardware NPI programs and sustain engineering for medical devices, managing cross-functional teams across US and Asia while integrating software platforms with hardware products. Requires 5+ years in hardware operations or TPM and a bachelor's in engineering or related field.