Sr. Systems Reliability Engineer

Zone 5 Technologies

2d•$148,000 - $219,000

About The Position

Zone 5 Technologies is seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle for unmanned aircraft systems. The role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. It involves direct engagement with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews. The engineer will develop and maintain R&M plans and architecture documentation; lead reliability analyses and requirements allocation; establish and manage failure reporting and corrective action processes; plan and oversee reliability growth and demonstration testing; and review test results for R&M compliance. The role also leads customer-facing reviews, failure investigations, and cross-functional risk mitigation, while applying digital engineering and AI-enabled tools and ensuring compliance with applicable R&M standards.

Requirements

At least 7 years as a Reliability Engineer, R&M Engineer, or in an equivalent reliability-critical engineering role.
Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics.
Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards.
Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure.
Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening.
Experience engaging with customers on R&M reviews and milestone/design reviews, including PDR, CDR, and Milestone B/C.
Strong system architecture knowledge and experience decomposing and allocating R&M requirements.
Extensive FMEA/FMECA, FTA, and RBD experience.
Failure investigation experience with proven corrective action implementation.
Technical writing experience with R&M program plans, rationale reports, procedures, and documentation.
Design review experience, including PDR, CDR, and MRR, with strong presentation skills.
Experience collecting, analyzing, and trending R&M metrics.
U.S. Citizenship.

Nice To Haves

Master's degree in engineering or a related field.
10 or more years of progressive R&M experience.
ASQ Certified Reliability Engineer (CRE) or equivalent certification.
DoD or Navy R&M program experience aligned with SECNAV Reliability and Maintainability Engineering guidance.
Quantitative reliability growth modeling experience, such as Crow-AMSAA, and Weibull analysis.
Maintainability, Testability/BIT, LORA, and RCM experience.
Missile, hypersonic, or munitions systems experience, including all-up-round reliability, environmental stress screening, and shelf-life/stockpile surveillance programs.
Digital engineering and AI-enabled R&M tools experience, including predictive maintenance, digital twins, and automated FRACAS analytics.
Active U.S. Security Clearance or ability to obtain one.

Responsibilities

Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C Rationale Report.
Lead FMEA/FMECA, Fault Tree Analysis, and Reliability Block Diagram development across system architecture.
Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support requirements analysis and trade studies.
Draft reliability predictions using MIL-HDBK-217 and related methods, and conduct maintainability analyses while maintaining traceability between requirements, predictions, and demonstrated performance.
Lead Reliability-Centered Maintenance and Level of Repair Analysis; support Testability and Built-In Test analysis.
Establish and own the FRACAS, maintaining closed-loop failure data collection and trending from design through test, production, and sustainment.
Develop Failure Definitions and Scoring Criteria and reliability test plans aligned with program milestones.
Lead reliability growth planning and reliability growth and demonstration testing, including ESS and HALT/HASS where applicable.
Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments.
Develop R&M technical documentation, including standards, specifications, procedures, and user guides.
Review ground, flight, and live-fire test data to confirm compliance with R&M requirements.
Serve as the primary customer point of contact on R&M matters.
Present R&M analyses, RAM-C Rationale Report updates, and risk posture at milestone and design reviews.
Lead Reliability Scoring Conferences and Corrective Action Boards with customer participation.
Coordinate responses to customer R&M data item deliverables and support In-Service Reviews.
Lead root cause and corrective action investigations for failures identified through FRACAS.
Host corrective action reviews and ensure lessons learned are implemented across the program.
Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence, shelf-life, and aging surveillance considerations.
Apply digital engineering and AI-enabled tools to R&M processes, including predictive maintenance, digital twins, and automated FRACAS analytics.
Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards.