What are the responsibilities and job description for the Failure Analysis Engineer position at HireReady Partners?
Position Summary
- The Failure Analysis Engineer (FAE) is responsible for investigating, analyzing, and identifying root causes of failures in electronic assemblies, systems, and components used in high-performance computing, server, and AI-related hardware products.
- This role supports continuous improvement and product reliability initiatives through data-driven analysis, cross-functional collaboration, and corrective action implementation.
- The FAE will leverage advanced diagnostic tools and methods to enhance product quality, manufacturing yields, and customer satisfaction.
- May oversee FA Technicians and provide technical guidance and training.
- Coordinates project assignments and ensures timely completion of analysis reports.
- Failure Analysis and Root Cause Investigation (50%)
- Perform electrical, mechanical, and thermal failure analysis on defective units from production, field returns (RMA), and reliability testing.
- Utilize analytical tools such as oscilloscopes, X-ray, SEM/EDS, decapsulation, and cross-sectioning for detailed investigation.
- Identify failure modes, document analysis results, and establish root cause and contributing factors.
- Correlate failures with design, process, and material data to support engineering improvements.
- Data Collection and Reporting (20%)
- Maintain detailed FA reports, including findings, corrective actions, and risk assessments.
- Present analysis summaries to internal engineering, manufacturing, and customer teams.
- Compile trend data on recurring failure modes and propose mitigation actions.
- Track metrics on failure rates, mean time between failure (MTBF), and reliability indicators.
- Cross-Functional Collaboration (15%)
- Partner with manufacturing, R&D, and quality engineering teams to drive corrective and preventive actions (CAPA).
- Support supplier quality teams in component failure validation and incoming inspection processes.
- Coordinate with customer support and warranty analysis teams on field failure investigations.
- Process and Product Improvement (10%)
- Participate in Design for Manufacturability (DFM) and Design for Reliability (DfR) reviews.
- Recommend design or process modifications to reduce defect rates and improve overall product robustness.
- Contribute to process control documentation and standard operating procedures (SOPs).
- Compliance and Safety (5%)
- Ensure all FA activities comply with ESD, ISO, and environmental standards (e.g., RoHS, REACH).
- Maintain lab equipment calibration and safe operating practices.
- Bachelor’s degree in Electrical Engineering, Materials Science, Mechanical Engineering, or related field required.
- Master’s degree or equivalent experience in Reliability Engineering, Failure Analysis, or Quality Engineering preferred.
- 3–5 years of experience in failure analysis or reliability engineering within electronics, semiconductor, or high-tech manufacturing industries.
- Experience with AI server systems, GPU boards, or data center hardware is a plus.
- Technical Skills:
- Proficiency with diagnostic equipment (oscilloscope, DMM, logic analyzer, X-ray, SEM, FIB, etc.)
- Knowledge of SMT manufacturing, solder joint analysis, and IPC standards.
- Familiarity with reliability testing (HALT, HASS, thermal cycling, vibration testing).
- Experience with data analysis tools (Python, JMP, Minitab, Excel).
- Ability to interpret schematics, layout drawings, and bill of materials (BOM).
- Core Competencies:
- Analytical Thinking: Strong ability to dissect complex problems and identify root causes.
- Technical Expertise: Deep understanding of electrical/electronic systems, PCB design, and semiconductor behavior.
- Collaboration: Works effectively with multidisciplinary teams to solve technical challenges.
- Communication: Ability to write clear, data-supported reports and present findings to technical and non-technical audiences.
- Continuous Improvement: Passion for enhancing product reliability and manufacturing efficiency
- Failure Analysis Turnaround Time (TAT)
- Root Cause Accuracy and Verification Rate
- Corrective Action Implementation Effectiveness
- Reduction in Recurrence Rate of Failures
- Customer Satisfaction (internal/external) with FA deliverables
- On-site role at our client’s Alliance, TX manufacturing facility.
- Exposure to electronics lab environments (ESD-safe areas, microscopes, soldering stations).
- Occasional travel to suppliers, customer sites, or corporate headquarters (domestic/international).
- Normal working hours with flexibility to support urgent FA cases and project deadlines.