Senior Failure Analysis Engineer

Johnson & Johnson•Santa Clara, CA

2d•Onsite

About The Position

The Robotics and Digital Solutions (RAD) group, part of the Johnson & Johnson family of companies, is recruiting for a Senior Failure Analysis Engineer for the Ottava R&D Reliability Team. This position is located in Santa Clara, CA. The Ottava R&D team envisions a future for robotic intervention that is targeted, minimally invasive, and personalized. Building upon a deep understanding of patient and physician needs, we are developing a platform for the next evolution of soft-tissue robotic care. We are a team of mechanical, electrical, mechatronics, robotic controls, software, and clinical engineers who are passionate about improving patient care. The team includes a wide range of experience levels from junior engineers to industry experts. We follow an iterative design approach to product development that requires us to collaborate closely across clinical, capital hardware, and instruments & accessories teams. We value autonomy and empower each other to take action while remaining a supportive and closely knit team. We take pride in our culture and are committed to building an environment that is inclusive and promotes diversity of thought through varied experiences and backgrounds. The Ottava Reliability Engineering team is responsible for ensuring system reliability, availability, maintainability, and long-term product performance throughout development, Early Access, and commercial deployment. The team drives reliability growth through data-driven engineering, reliability testing, field performance monitoring, and root cause investigation. As the Senior Failure Analysis Engineer, you will play a key role in advancing the reliability of the OTTAVA surgical robotic platform by leading the Hardware Team’s Failure Analysis (FA) capability. In this role, you will serve as the technical lead for complex investigations across development, verification, manufacturing, service, and field-returned systems. You will establish robust investigation methodologies, develop laboratory capabilities, manage analytical equipment and external laboratory partnerships, and help strengthen structured root cause analysis practices across engineering teams. This role offers the opportunity to combine hands-on technical investigation with process development, laboratory ownership, and cross-functional leadership to build a scalable Failure Analysis function that supports product reliability and continuous improvement throughout the Ottava lifecycle.

Requirements

Bachelor's degree in Mechanical Engineering, Materials Science, Electrical Engineering, Biomedical Engineering, Physics, or a related technical field.
5+ years of experience in failure analysis, root cause investigation, reliability engineering, product quality, product development, or a related technical discipline.
Demonstrated success leading complex, cross-functional investigations and driving technical issues from problem identification through root cause determination, corrective action, and resolution.
Strong understanding of physics-of-failure principles and structured problem-solving methodologies, with the ability to apply data-driven approaches to challenging technical problems.
Hands-on experience utilizing a variety of failure analysis and characterization techniques, such as microscopy, SEM/EDS, CT/X-ray imaging, metallography, contamination analysis, cross-sectioning, materials characterization, electrical troubleshooting, and mechanical testing.
Working knowledge of reliability engineering concepts and tools, including FMEA, Weibull analysis, reliability growth methodologies, and Design for Reliability (DfR) practices.
Experience developing, expanding, or enhancing failure analysis capabilities, laboratories, technical processes, or organizational functions.
Excellent analytical, communication, and collaboration skills, with the ability to influence stakeholders and effectively communicate complex technical findings to diverse audiences.
Passion for solving difficult technical challenges and improving product performance, quality, and reliability.

Nice To Haves

Advanced Degree in related technical fields
Experience in a regulated or highly engineered industry, such as medical devices, robotics, aerospace, automotive, semiconductor, life sciences, or related fields.

Responsibilities

Lead complex mechanical, electrical, electromechanical, and system-level failure investigations, driving issues from initial assessment through root cause identification, corrective action, and successful resolution.
Partner closely with Design Engineering teams to translate investigation findings into meaningful product and design improvements that enhance quality, reliability, and customer experience.
Ensure learnings from investigations are integrated into design controls, risk assessments, FMEAs, reliability strategies, manufacturing processes, and service procedures.
Collaborate with Reliability Engineering to leverage failure analysis insights and accelerate reliability growth initiatives across the product lifecycle.
Coordinate and oversee advanced analytical testing, including materials characterization, microscopy, contamination analysis, chemical analysis, and advanced imaging techniques.
Support product quality and reliability efforts through complaint investigations, field-return analysis, manufacturing nonconformance investigations, and reliability testing activities.
Clearly communicate technical findings, recommendations, and business impact to technical and non-technical stakeholders, including senior leadership.
Establish and monitor key performance indicators to measure investigation effectiveness, recurrence prevention, cycle time, and organizational learning.
Develop and execute the long-term vision, strategy, and roadmap for Failure Analysis capabilities, including laboratory infrastructure, equipment, and technology investments.
Build and maintain laboratory processes that promote operational excellence, including safety, sample handling, calibration, equipment maintenance, and resource utilization.
Serve as the primary technical interface for external analytical laboratories, testing partners, and specialized service providers.
Facilitate cross-functional problem-solving efforts using structured methodologies such as 8D, 5-Why, Fishbone Analysis, Fault Tree Analysis (FTA), Root Cause Analysis (RCA), and data-driven decision making.
Define, implement, and continuously improve failure analysis workflows, procedures, standards, templates, and best practices to enhance efficiency, consistency, and quality.