Senior Engineer, Failure Analysis

The Allegro team is united by a clear purpose—advancing technologies that make the world safer, more efficient, and more sustainable. With over 30 years of experience in semiconductor innovation, we bring that purpose to life across every part of the business—from breakthrough product development and customer success to how we show up for each other and the communities we serve.

The Opportunity 

As a Senior Failure Analysis Engineer, you will be a key technical leader, responsible for tackling the most complex product failure investigations. Your advanced expertise will be critical in maintaining our rigorous quality standards, enhancing product reliability, and directly influencing the design and manufacturing processes of our cutting-edge semiconductor devices. This role offers an opportunity to lead technical efforts and mentor junior engineers within a dynamic and innovative environment.

What You Will Do 

• Lead and perform comprehensive non-destructive and destructive failure analysis techniques on highly complex samples in response to critical customer complaints, significant product returns (STR), and challenging manufacturing failures.

• Generate, review, and critically evaluate detailed failure analysis reports, providing clear, concise, and actionable conclusions for various stakeholders.

• Expertly operate, maintain, and troubleshoot a wide range of specialized Failure Analysis (FA) equipment, instruments, and tools, including optical microscopes, X-ray inspection systems, acoustic microscopy (CSAM), scanning electron microscopes (SEM) with energy dispersive X-ray spectroscopy (EDX) for elemental analysis, micro-sectioning equipment, advanced decapsulation tools (LASER, mechanical, chemical), sophisticated electrical bench testing instruments (e.g., curve tracers, multi-temperature testers, precision power supplies, multimeters, signal generators, oscilloscopes), fume hoods and chemical handling apparatus, polishing and parallel lapping equipment, and microprobers.

• Develop and refine failure analysis methodologies and processes to enhance diagnostic capabilities and efficiency.

• Apply advanced chemical deprocessing techniques to expose internal device components for in-depth inspection and analysis.

• Oversee and perform complex sample preparation for analysis, including intricate lead rework, soldering/desoldering, and advanced PCB/module extraction.

• Interpret and correlate complex Automated Test Equipment (ATE) and bench test results, driving failure isolation down to the deepest IC schematic and layout levels.

• Provide expert technical leadership, guidance, and mentorship to Failure Analysis (VoF) technicians and junior FA lab staff.

• Collaborate proactively and strategically with Requestors, Quality, Applications, Test, Product, and Design Engineers to ensure highly efficient and effective FA investigations of critical customer returns and internal issues.

• Critically review and thoroughly understand complex customer complaints and internal issues to develop comprehensive FA plans, allocate resources, and define timelines prior to analysis.

• Drive continuous improvement initiatives within the FA lab, including equipment upgrades, process optimization, and training programs.

What You Will Bring 

• A Bachelor's degree in Engineering (Electronics, Electrical) or Physics, or Material Science; a Master's degree is preferred.

• 5+ years of progressive experience in Semiconductor Failure Analysis, demonstrating expertise in both non-destructive and destructive testing techniques.

• Advanced knowledge and hands-on experience operating a comprehensive suite of electrical instruments and bench testing tools (e.g., precision power supply, advanced multimeter, signal generator, high-bandwidth oscilloscope, I/V curve trace tester).

• Expert-level familiarity with the principles, operation, and maintenance of key FA equipment, including advanced CSAM, high-resolution X-ray, optical microscopes, SEM/EDX, fume hoods, and precision sectioning tools.

• A strong, in-depth background in semiconductor electronics industry operations and processes, encompassing Assembly, advanced IC Fabrication, comprehensive Testing and Validation (including complex applications circuits), detailed circuit schematics diagram/layout analysis and advanced ATE datalog review, proficient programming skills, rigorous chemicals and laboratory safety protocols, and a thorough understanding of Quality Management Systems.

• Expertise in fault isolation techniques (e.g., advanced Emission Microscopy, Thermal Analysis, OBIRCH), intricate IC delayering processes, safe chemical handling, and precision microprobing.

• Demonstrated ability to lead technical projects and mentor junior engineers.

• Excellent analytical and problem-solving skills with a proven track record of resolving complex technical issues.

• Superior written and verbal communication skills, capable of presenting complex technical information to diverse audiences.

• Proficiency in computer applications, including Microsoft Word, Excel, PowerPoint, advanced photo-editing software, and relevant programming languages for data analysis and automation.