Sr. Staff Failure Analysis Engineer

Bloom Energy•San Jose, CA

2d•Onsite

About The Position

Bloom Energy is seeking a Senior Staff Failure Analysis Engineer to investigate failures of parts returned from the field, primarily balance-of-plant (BOP) components. The role is based in San Jose, California, and is fully onsite in an office. The engineer will assess field operating conditions, plan systematic teardowns and measurements, identify root causes, and document findings with detailed descriptions, photographs, measurements, and conclusions. The role works with internal teams and third-party laboratories as needed to conduct analyses and address failures quickly. The engineer will coordinate with service, quality, reliability, supply chain, logistics, factory, design, controls, data analytics, and fleet analytics teams to mitigate current failures, prevent recurrence, and improve future products. Responsibilities include establishing failure-analysis metrics and sampling plans, supporting testing of failure modes, improving product diagnostics and early detection of field issues, and sharing failure-mode information to enable proactive fleet action. Technical work includes first- and second-level analysis of fuel-cell components, BOP and hot-box parts, and server parts; evaluating parts against specifications and use cases; conducting root-cause and corrective-action work; documenting results in FRACAS or other systems; coordinating supplier RMAs; containing suspect product populations; and analyzing statistical data to support product quality and reliability. The position also assists the reliability group with predicting or analyzing part failure rates. The role requires at least eight years of technical work experience, a relevant engineering, materials science, or physics degree, practical statistical methods experience, and the ability to establish credibility with engineering staff and work effectively across functions. Travel may be 0–20% of the time. The listed salary range is $134,500–$193,500.

Requirements

Bachelor’s or master’s degree in Mechanical Engineering, Electrical Engineering, Industrial Engineering, Materials Science, or Physics.
At least 8 years of technical work experience.
Knowledge of failure-analysis techniques and tools.
Ability to establish technical credibility with engineering staff.
Hands-on approach to completing work.
Strong interpersonal skills and ability to establish effective cross-functional working relationships.
Ability to participate effectively on multidisciplinary teams.
Proficiency in MS Office Suite, including Word, Excel, PowerPoint, and databases.
Ability to prepare and effectively present formal reports to internal and external customers.
Practical working knowledge and application of SPC.
Proficiency in applying DOEs and ANOVA.
Strong internal and external customer focus.
Flexibility in a rapidly changing, dynamic work environment.
Demonstrated self-initiative and sound judgment on technical projects and improvement initiatives.
Bias for action and ability to multitask.
Ability to travel 0–20% of the time.

Responsibilities

Obtain field-returned parts, investigate field operating conditions, and determine failure causes.
Plan systematic teardowns and measurements to identify root causes, prioritizing fast-track analysis for critical parts.
Document failure-analysis results in detail, including written descriptions, photographs, measurements, evidence, and conclusions.
Work with in-house engineers and quality personnel to use available analysis equipment, and engage third-party laboratories when needed.
Coordinate cross-functionally with Service, Install Quality, Reliability, SQE, and Logistics to address failures quickly.
Work with Factory, Design, Install Quality, and SQE to mitigate and prevent failures.
Incorporate lessons learned into next-generation products.
Create metrics for failed parts and failure-analysis turnaround times.
Determine sampling plans when repeated symptoms indicate a known problem.
Work with Engineering to activate and deactivate failure modes in testing.
Coordinate with controls and data analytics teams to detect early symptoms of field issues.
Work with Engineering to improve product self-diagnostics and annunciation of potential failures based on monitored values.
Inform the Fleet Analytics leader of potential failure modes and indicative symptoms to support proactive fleet sweeps.
Perform first- and second-level failure analysis of fuel-cell components, primarily BOP parts, as well as BOP, hot-box, and server parts.
Evaluate parts against technical specifications and use cases, comparing them with actual condition.
Conduct root-cause and corrective-action work, prescribe corrective and preventive actions, and verify or validate their effectiveness.
Record analysis results using the FRACAS process or other systems.
Work with SQE to document supplier-part RMA returns for field failures.
Work with Quality to contain suspect product ranges and coordinate proactive repair, inspection, or return of affected field populations.
Develop and analyze statistical data to establish standards and ensure product quality and reliability expectations.
Assist the reliability group in predicting or analyzing part failure rates based on failure modes.
Collaborate with Field Service on efficient methods for conducting failure analysis.
Travel 0–20% of the time.