Failure Analysis Engineer

Donato Technologies Inc•Grapevine, TX

2d•$60,000 - $70,000•Onsite

About The Position

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.

Requirements

Bachelor’s degree in Electrical Engineering, Materials Science, Mechanical Engineering, or related field required.
3–5 years of experience in failure analysis or reliability engineering within electronics, semiconductor, or high-tech manufacturing industries.
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).
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

Nice To Haves

Master’s degree or equivalent experience in Reliability Engineering, Failure Analysis, or Quality Engineering preferred.
Experience with AI server systems, GPU boards, or data center hardware is a plus.

Responsibilities

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.
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.
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.
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).
Ensure all FA activities comply with ESD, ISO, and environmental standards (e.g., RoHS, REACH).
Maintain lab equipment calibration and safe operating practices.