Senior Quality Control Engineer- Failure Analysis Investigations

Rolls-Royce•Aiken, SC

8d•Onsite

About The Position

The Senior Quality Engineer – Failure Analysis Investigations plays a critical role in leading engine failure investigations, identifying root causes, implementing corrective actions, and driving continuous product quality improvements. This position serves as the technical lead for complex diesel engine failure investigations and provides timely communication to management and cross-functional teams. Rolls-Royce Power Systems is a business that delivers world-class solutions that power critical infrastructure across energy, industrial, marine, and defense sectors. North America is a key growth market for our Power Systems business, driven by increasing demand for resilient energy solutions, data center expansion, and the transition to more sustainable power. As we continue to invest and expand across the region, our teams are at the forefront of this growth, advancing innovative technologies and shaping the future of reliable, sustainable power.

Requirements

Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Quality Engineering, or a related engineering discipline.
Applicants must be authorized to work for any employer in the U.S without sponsorship.
We are unable to sponsor or take over sponsorship of an employment Visa at this time.

Nice To Haves

Experience with diesel engine manufacturers
Knowledge of MTU products and components.
Experience with laboratory testing methods, metallurgical analysis, and non-destructive testing techniques.
Strong understanding of engine performance requirements, reliability engineering, and product validation processes.

Responsibilities

Lead and coordinate investigations related to internal combustion engine failures, field issues, warranty claims, and manufacturing defects.
Establish and manage cross-functional investigation teams including Quality, Engineering, Manufacturing, Service, and Supplier Quality.
Develop investigation plans and ensure timely completion of containment, root cause analysis, and corrective actions.
Perform detailed failure analysis on engine components, including mechanical, electrical, fuel, lubrication, cooling, and combustion systems.
Utilize structured problem-solving methodologies such as 8D, 5 Why, Fishbone Diagram, Fault Tree Analysis, and Kepner-Tregoe techniques.
Analyze test data, inspection reports, field information, and physical evidence to determine root causes.
Lead corrective and preventive action implementation to prevent recurrence.
Validate effectiveness of corrective actions through testing and data analysis.
Prepare detailed technical investigation reports and present findings to senior leadership and global stakeholders.
Provide timely status updates to management regarding investigation progress, risks, and mitigation plans.
Develop technical presentations and executive summaries for management reviews.
Maintain accurate documentation of investigations, lessons learned, and knowledge databases.
Collaborate closely with Product Engineering, Manufacturing Engineering, Service, Supplier Quality, and Operations teams.
Interface with suppliers and external laboratories when component testing or specialized analysis is required.
Support customer issue resolution activities and participate in customer meetings as needed.
Provide technical recommendations for product and process improvements.
Identify recurring failure trends and drive projects to improve product reliability and quality performance.
Support reliability growth initiatives and implementation of preventive measures.
Develop and maintain failure analysis procedures, standards, and best practices.
Lead special projects related to engine quality improvement and operational excellence.
Mentor engineers and team members on failure analysis methodologies and structured problem solving.
Provide training on 8D methodology, root cause analysis tools, and lessons learned from investigations.
Support development of organizational knowledge related to diesel engine failures and reliability.
Support strategic quality initiatives and special assignments to improve product quality, reliability, and customer satisfaction.