The Role
Lead hardware FMEA, reliability analysis, risk mitigation, qualification testing, failure analysis, and reliability growth activities across electronic, electrical, and electromechanical products. Develop test strategies, analyze reliability data, oversee environmental and stress testing, and drive corrective actions in collaboration with design, manufacturing, quality, supplier, and engineering teams.
Summary Generated by Built In
Job Summary
We are seeking a highly motivated Hardware FMEA & Reliability Engineer to drive product reliability and risk assessment activities throughout the product development lifecycle. The candidate will be responsible for conducting Design FMEA (DFMEA), Process FMEA (PFMEA), reliability analysis, and qualification testing for electronic, electrical, and electromechanical hardware systems. The role requires close collaboration with design, manufacturing, quality, and supplier teams to ensure robust, reliable, and high-quality products.
Key Responsibilities
FMEA & Risk Analysis
We are seeking a highly motivated Hardware FMEA & Reliability Engineer to drive product reliability and risk assessment activities throughout the product development lifecycle. The candidate will be responsible for conducting Design FMEA (DFMEA), Process FMEA (PFMEA), reliability analysis, and qualification testing for electronic, electrical, and electromechanical hardware systems. The role requires close collaboration with design, manufacturing, quality, and supplier teams to ensure robust, reliable, and high-quality products.
Key Responsibilities
FMEA & Risk Analysis
- Lead and facilitate Design Failure Mode and Effects Analysis (DFMEA) and Process Failure Mode and Effects Analysis (PFMEA) activities for hardware products.
- Identify potential failure modes, root causes, and failure mechanisms across electrical, electronic, mechanical, and system-level designs.
- Evaluate severity, occurrence, and detection ratings and develop risk mitigation plans.
- Maintain and update FMEA documentation throughout the product lifecycle.
- Track corrective and preventive actions resulting from FMEA reviews.
- Support design reviews and ensure identified risks are addressed before product release.
- Develop reliability requirements, reliability growth plans, and qualification test strategies.
- Perform reliability predictions and analyses using industry standards such as MIL-HDBK-217, Telcordia SR-332, IEC, or equivalent methodologies.
- Conduct Failure Analysis (FA), Root Cause Analysis (RCA), and corrective action implementation.
- Analyze field returns, reliability data, and failure trends to improve product robustness.
- Establish reliability metrics including MTBF, MTTF, FIT rates, and failure distributions.
- Define and execute hardware reliability and environmental qualification test plans.
- Coordinate and oversee testing including:
- Temperature Cycling
- Thermal Shock
- High Temperature Operating Life (HTOL)
- Burn-In Testing
- Highly Accelerated Life Testing (HALT)
- Highly Accelerated Stress Screening (HASS)
- Vibration Testing
- Mechanical Shock Testing
- Humidity Testing
- Salt Fog / Corrosion Testing
- Power Cycling
- Electrical Overstress Testing
- EMC/EMI Reliability Verification
- Safety and Regulatory Compliance Testing
- Analyze test results and recommend design improvements based on findings.
- Generate qualification reports and reliability assessment documentation.
- Work closely with hardware design, PCB design, mechanical engineering, manufacturing, quality, and supplier teams.
- Participate in design verification and validation activities.
- Support supplier qualification and component reliability assessments.
- Drive reliability best practices and lessons learned across engineering teams.
- Bachelor's or Master's degree in Electrical Engineering, Electronics Engineering, Mechanical Engineering, Reliability Engineering, or related field.
- 5+ years of experience in hardware development, reliability engineering, or product qualification.
- Strong knowledge of DFMEA, PFMEA, FTA (Fault Tree Analysis), and risk management methodologies.
- Experience with electronic assemblies, PCBAs, power electronics, electromechanical systems, and hardware qualification testing.
- Familiarity with reliability standards such as IEC, JEDEC, Telcordia, MIL-HDBK-217, and IPC standards.
- Experience with statistical analysis, Weibull analysis, and reliability modeling.
- Strong problem-solving, root-cause analysis, and technical documentation skills.
- Experience with high-voltage systems, industrial equipment, semiconductor equipment, or complex electromechanical products.
- Knowledge of accelerated life testing methodologies and reliability growth modeling.
- Six Sigma, ASQ Reliability Engineer, or equivalent certification.
- Experience with reliability tools such as ReliaSoft, Windchill Quality Solutions, Minitab, JMP, or equivalent.
Skills Required
- Bachelor’s or Master’s degree in Electrical Engineering, Electronics Engineering, Mechanical Engineering, Reliability Engineering, or a related field
- 5+ years of experience in hardware development, reliability engineering, or product qualification
- Strong knowledge of DFMEA, PFMEA, FTA, and risk management methodologies
- Experience with electronic assemblies, PCBAs, power electronics, electromechanical systems, and hardware qualification testing
- Familiarity with IEC, JEDEC, Telcordia, MIL-HDBK-217, and IPC standards
- Experience with statistical analysis, Weibull analysis, and reliability modeling
- Strong problem-solving, root-cause analysis, and technical documentation skills
- Experience with high-voltage systems, industrial equipment, semiconductor equipment, or complex electromechanical products
- Knowledge of accelerated life testing methodologies and reliability growth modeling
- Six Sigma, ASQ Reliability Engineer, or equivalent certification
- Experience with ReliaSoft, Windchill Quality Solutions, Minitab, JMP, or equivalent reliability tools
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The Company
What We Do
Zealogics LLC provides a broad range of IT consulting, systems implementation and application outsourcing services through an optimized global delivery model. Zealogics builds deep knowledge of traditional product engineering across mechanical, electronics and software platforms, to enable clients to navigate their digital transformation. Zealogics values engineering techniques, automation frameworks, and reference models which are refined through engagements with Fortune 500 enterprises and OEMs. We combine customer-centric product strategies through a collaborative approach for execution. We help to harmonize processes, identify bottlenecks, and eliminate non-value tasks to deliver world-class products. With impeccable focus on client needs we connect specialized resources for the right positions, both for full time and contractual placements. Our long-term relationships with employees and clients have been built in an environment of integrity and commitment, with a shared goal of mutual success. Zealogics hires experienced people to solve a wide array of IT and Engineering challenges that our clients face. Our guarantee - Zealogics provides the best value services in town.
