Failure Analysis Engineer

CAI•Hampton, VA

2d•$55 - $60•Onsite

About The Position

We are looking for a Failure Analysis Engineer to be a crucial member of the Failure Analysis and Engineering team responsible for investigating product failures, manufacturing issues, customer complaints, and field returns. This position will be Full-Time and On-Site in Hampton, VA. This position involves access to information and hardware subject to the International Traffic in Arms Regulations (ITAR) and/or Export Administration Regulations (EAR). Candidates must be a U.S. Person as defined by ITAR (U.S. citizen, U.S. permanent resident, or protected individual).

Requirements

B.S. degree in Materials Engineering, Mechanical Engineering, Electrical Engineering, Physics, Chemistry, or related technical field
Minimum 3-5 years of experience in Failure Analysis, Materials Engineering, Reliability Engineering, Product Engineering, Quality Engineering, or related technical discipline
Hands-on experience performing root cause investigations and failure analysis activities
Knowledge of analytical and laboratory techniques such as microscopy, metallography, cross-sectioning, SEM/EDS, X-ray, FTIR, DSC, or related methods
Strong understanding of engineering problem-solving methodologies including 8D, 5 Why, Fishbone, and Fault Tree Analysis
Experience supporting customer complaint investigations and corrective action activities
Ability to interpret technical drawings, specifications, product requirements, and engineering documentation

Nice To Haves

Knowledge of quality systems and standards such as ISO 9001, IATF 16949, ISO 13485, or AS9100
Experience using statistical software and analysis tools such as Minitab
Six Sigma Green Belt, Red X, or equivalent problem-solving certification
Excellent technical report writing and communication skills
Ability to independently manage multiple investigations and prioritize activities

Responsibilities

Perform failure analysis on customer returns, warranty claims, manufacturing defects, reliability failures, and field returns
Conduct non-destructive and destructive analysis to determine failure modes and mechanisms
Utilize analytical techniques, including microscopy, cross-section analysis, material characterization, X-ray inspection, and SEM/EDS
Prepare samples and perform laboratory investigations according to established procedures and best practices
Generate clear and concise technical reports documenting observations, findings, conclusions, and recommendations
Support root cause investigations using structured methodologies such as 8D, 5 Why, Fishbone, Fault Tree Analysis (FTA), and/or Red X
Collaborate with Product Engineering, Manufacturing Engineering, Quality Engineering, and Operations teams to resolve complex technical issues
Participate in customer complaint investigations and provide technical evidence supporting corrective and preventive actions
Support manufacturing sites in resolving scrap, yield, process, and field reliability issues
Analyze trends in failure data and identify recurring failure mechanisms or systemic issues
Contribute to product reliability improvements through understanding failure mechanisms and risk reduction recommendations
Support DFMEA, PFMEA, and Lessons Learned activities through technical findings
Maintain records, analysis reports, and documentation in compliance with applicable quality management system requirements
Participate in continuous improvement initiatives focused on quality, reliability, cost reduction, and customer satisfaction
Work effectively in a cross-functional and global environment supporting multiple manufacturing sites and business units