Staff Electrical Failure Analysis Engineer (NJ)
Core
Lead electrical root cause analysis (RCA), failure characterization, and corrective action activities across server, rack, cable, connector, and electromechanical hardware platforms to improve product quality, reliability, and manufacturing yield.
Role type
Staff Electrical Failure Analysis Engineer
Builds
High-volume manufacturing environments for server, rack, cable, connector, and electromechanical hardware platforms
Domain
Hardware manufacturing, electrical engineering, reliability engineering
Deliverable
production ML models | product features | dashboards & analysis | research | client delivery | infrastructure | physical/clinical work
Required skills
electrical troubleshooting, root cause analysis, fault isolation, statistical analysis, structured problem-solving (8D, DMAIC, CAPA, FMEA), reading electrical schematics, supplier quality investigations, data trend analysis
Preferred skills
Al server/data center hardware experience, cable assembly/wire harness expertise, TDR usage, Vector Network Analyzer (VNA) operation, high-speed interconnect knowledge (PCIe, Ethernet, InfiniBand), IPC/WHMA-A-620 certification, Six Sigma Green/Black Belt
Technologies
Digital Multimeters (DMM), Oscilloscopes, LCR Meters, Power Supplies, Continuity Testers, Insulation Resistance Test Equipment, TDR, VNA
Responsibilities
Lead electrical failure investigations involving connectors, cable assemblies, wire harnesses, power distribution systems, and electromechanical components; Perform root cause analysis of electrical defects including opens, shorts, intermittent connections, excessive resistance, insulation breakdown, and ESD-related failures; Develop and execute fault isolation plans using electrical test equipment and laboratory analysis techniques; Correlate electrical failure signatures with dimensional, mechanical, and metrology data to identify failure mechanisms and process drivers; Drive containment, corrective actions, and preventive actions through structured methodologies including 8D, DMAIC, and CAPA processes; Partner with Manufacturing, Supplier Quality, and Engineering teams to resolve electrical nonconformances and improve product reliability; Develop electrical test methods, inspection procedures, and validation protocols to support manufacturing and quality operations; Support qualification, reliability, and environmental testing activities including thermal cycling, vibration, HALT, and HASS investigations; Analyze failure trends, field return data, and manufacturing defects to identify recurring issues and improvement opportunities; Review engineering drawings, schematics, wiring diagrams, and specifications to support failure analysis activities; Generate detailed technical reports documenting failure mechanisms, root causes, test results, and corrective actions; Support supplier audits, supplier corrective actions, and component qualification activities related to electrical and cable assembly suppliers
Seniority
Staff, hands-on IC with strategic influence
