Reliability & Failure Analysis Engineer

Sesame • San Francisco, CA

13d • $175,000 - $280,000

About The Position

As a Reliability and FA Engineer at Sesame, you will be responsible for ensuring the quality, robustness, and longevity of our consumer products. You will define and execute comprehensive reliability test plans, conduct deep-dive failure analysis (FA) on units from testing and field returns, and drive root cause identification and corrective actions. This role requires a strong technical leader who can bridge the gap between design validation and mass production, partnering with cross-functional teams to influence design for reliability (DFR) and ensure our products meet rigorous performance standards.

Requirements

• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Materials Science, or a related technical field.
• 7+ years of relevant experience in reliability engineering or failure analysis within the consumer electronics industry.
• Hands-on experience with failure analysis tools and techniques, such as X-ray, cross-sectioning, SEM, or optical microscopy.
• Deep understanding of industry-standard reliability testing methodologies and environmental standards.
• Strong problem-solving, communication, and interpersonal skills, with the ability to articulate complex technical findings to diverse teams.

Nice To Haves

• 10+ years of experience in consumer electronics, with a focus on reliability and failure analysis.
• Master’s degree or PhD in Engineering or a related field.
• Proven experience with wearable devices or small form factor, high-density products.
• Experience with statistical analysis software (e.g., JMP, Minitab) and data-driven reliability modeling (e.g., Weibull analysis).
• Demonstrated success in influencing design decisions to improve product robustness and yield.

Responsibilities

• Define and execute reliability test plans, including Highly Accelerated Life Testing (HALT), Accelerated Life Testing (ALT), and environmental stress testing.
• Conduct comprehensive failure analysis (FA) on failed units from development, production, and field returns, using advanced analytical techniques and equipment.
• Drive root cause analysis (RCA) and collaborate with cross-functional engineering teams (Mechanical, Electrical, Firmware) to implement effective corrective and preventive actions (CAPA).
• Influence product architecture and design by implementing Design for Reliability (DFR) principles during early development phases.
• Manage reliability lab operations, including equipment maintenance, calibration, and safety protocols.
• Partner with internal and external teams to standardize reliability testing methodologies and validation criteria.
• Support product lifecycle management, from early prototype evaluation through mass production and beyond.
• Develop and maintain technical reports, reliability dashboards, and documentation on product performance trends.

Benefits

• 401 (k) max employer match: 3.5% of compensation
• 100% employer-paid health, vision, and dental benefits for you and your dependents
• Unlimited PTO and sick time
• Flexible spending account with employer matching up to $1,650/year (medical FSA)
• Guardian Employee Assistance Program (EAP)
• Opportunity to share in the company's success with competitive stock options

What This Job Offers

• Job Type: Full-time
• Career Level: Senior