Staff Failure Analysis Engineer

Agility Robotics•Salem, OR

8d•$147,000 - $191,000•Onsite

About The Position

Agility Robotics is seeking an experienced Field Failure Analysis Engineer to lead technical investigations into electromechanical, hardware, and system-level failures across deployed Digit fleets. The role connects field operations and customer deployments with engineering teams to contain field failures, identify physics-of-failure mechanisms, and drive corrective and preventive actions into manufacturing and future product designs. The engineer will investigate returned modules and correlate physical failure modes with fleet telemetry, system logs, and sensor data. They will lead structured root-cause analysis and CAPA efforts, establish field containment and inspection procedures, oversee internal and external failure-analysis testing, standardize return and depot workflows, and report fleet quality and failure trends to engineering and operations leadership. The position is based onsite at Agility Robotics’ Salem, Oregon facility, with regular presence in testing labs, service centers, and assembly lines. Travel of up to 20% to customer logistics centers, field trial sites, or suppliers is expected. Applicants must be authorized to work in the United States.

Requirements

Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Systems Engineering, or equivalent practical experience.
At least 6 years of hands-on failure analysis, field quality, or reliability engineering experience supporting complex electromechanical systems.
Demonstrated ability to troubleshoot cross-domain issues involving mechanical stress or wear, electrical signal degradation, motor-drive failures, and firmware/sensor interactions.
Practical mastery of 8D, Fault Tree Analysis, FMEA, and Ishikawa diagrams, with verified corrective actions that eliminated field failure modes.
Proficiency with bench diagnostic tools, including DMMs, high-bandwidth oscilloscopes, logic analyzers, optical microscopy, thermal cameras, and torque test fixtures.

Nice To Haves

Experience with Linux, ROS, CAN/EtherCAT protocol analyzers, and cloud-based time-series visualization tools such as Grafana, Datadog, or custom fleet dashboards.
Working knowledge of functional safety considerations, including ISO 13849 and IEC 62061, in industrial automation or mobile robotics.
Experience managing third-party destructive and non-destructive testing labs, including SEM, EDX, and X-ray/CT scanning.
ASQ certification (CQE or CRE) or Lean Six Sigma Green Belt or Black Belt.

Responsibilities

Lead end-to-end physical and system failure investigations on field-returned modules, including actuators, gearboxes, cable harnesses, PCBAs, motor controllers, safety sensors, and battery management systems.
Correlate physical failure modes with fleet telemetry, CAN/EtherCAT logs, crash dumps, and time-series sensor data, and reproduce field anomalies in lab environments.
Lead structured problem-solving and 8D/CAPA execution for critical field excursions, partnering with Design Engineering, Manufacturing Quality, and Supplier Quality to drive permanent reliability and serviceability improvements.
Define immediate containment protocols, triage criteria, and inspection work instructions for field technicians and customer-support teams during safety-critical or fleet-wide failure events.
Oversee internal failure-analysis lab equipment and coordinate external analytical testing such as CT scanning, SEM/EDX, cross-sectioning, and metallurgical analysis.
Establish standardized teardown procedures, failure-code taxonomies, and disposition tracking across repair depots and Salem assembly facilities.
Analyze fleet return rates, Mean Time Between Incidents, and component failure modes, and provide Pareto metrics and technical executive summaries to engineering and operations leadership.

Benefits

401(k) plan with a 6% company match.
Company stock options.
Company-paid medical, dental, vision, and short- and long-term disability insurance for employees.
Benefits eligibility beginning on the first day of employment.
Employee Assistance Program.
Flexible, unlimited PTO and 12 company holidays, including a winter shutdown, for exempt employees.
For non-exempt employees: 10 annual vacation days, paid sick leave, and 12 company holidays, including a winter shutdown.
Catered lunches four times a week and healthy snacks and refreshments at Salem and Pittsburgh locations.
Paid parental leave programs.
Flexible work arrangements.
Professional development and tuition reimbursement programs.
Relocation assistance for eligible roles.
Annual discretionary bonus for eligible roles.