Failure Analysis Engineer

Cephas Consultancy Services Private Limited

United States, Texas, Fort Worth - Fort Worth Alliance

On-site · Full-time

Failure Analysis Engineer

Location: Fort Worth Alliance, Texas, United States
Job ID: CLI-45654-5
Employment Type: Direct hire
Work Arrangement: On-site

Position Summary

The Failure Analysis Engineer investigates, analyzes, and identifies the root causes of failures in electronic assemblies, systems, and components used in high-performance computing, server, and AI-related hardware products. This role supports continuous improvement and product reliability initiatives through data-driven analysis, cross-functional collaboration, and corrective-action implementation.

Supervisory Responsibilities

  • May oversee Failure Analysis Technicians.
  • Provide technical guidance and training.
  • Coordinate project assignments and ensure the timely completion of analysis reports.

Key Responsibilities

Failure Analysis and Root-Cause Investigation — 50%

  • Perform electrical, mechanical, and thermal failure analysis on defective units from production, field returns, and reliability testing.
  • Use oscilloscopes, X-ray, SEM/EDS, decapsulation, cross-sectioning, and other analytical tools.
  • Identify failure modes and establish root causes and contributing factors.
  • Correlate failures with design, process, and material data to support engineering improvements.

Data Collection and Reporting — 20%

  • Maintain detailed failure-analysis reports covering findings, corrective actions, and risk assessments.
  • Present analysis summaries to engineering, manufacturing, and customer teams.
  • Compile recurring-failure trends and propose mitigation actions.
  • Track failure rates, MTBF, and reliability indicators.

Cross-Functional Collaboration — 15%

  • Partner with manufacturing, R&D, and quality engineering teams on corrective and preventive actions.
  • Support supplier quality teams with component-failure validation and incoming inspection.
  • Coordinate field-failure investigations with customer support and warranty-analysis teams.

Process and Product Improvement — 10%

  • Participate in Design for Manufacturability and Design for Reliability reviews.
  • Recommend design and process changes to reduce defects and improve product robustness.
  • Contribute to process-control documentation and standard operating procedures.

Compliance and Safety — 5%

  • Ensure compliance with ESD, ISO, RoHS, REACH, and environmental requirements.
  • Maintain laboratory-equipment calibration and safe operating practices.

Qualifications

  • Bachelor’s degree in Electrical Engineering, Materials Science, Mechanical Engineering, or a related field.
  • Master’s degree or equivalent experience in Reliability Engineering, Failure Analysis, or Quality Engineering preferred.
  • 3–5 years of experience in failure analysis or reliability engineering within electronics, semiconductor, or high-tech manufacturing.
  • Experience with AI server systems, GPU boards, or data-center hardware is a plus.

Technical Skills

  • Diagnostic equipment, including oscilloscopes, DMMs, logic analyzers, X-ray, SEM, and FIB.
  • SMT manufacturing, solder-joint analysis, and IPC standards.
  • Reliability testing, such as HALT, HASS, thermal cycling, and vibration testing.
  • Data-analysis tools, including Python, JMP, Minitab, and Excel.
  • Ability to interpret schematics, layout drawings, and bills of materials.

Core Competencies

  • Analytical thinking and root-cause investigation.
  • Strong electrical, electronic, PCB, and semiconductor knowledge.
  • Cross-functional collaboration.
  • Clear technical and non-technical communication.
  • Commitment to continuous improvement and product reliability.

Performance Indicators

  • Failure-analysis turnaround time.
  • Root-cause accuracy and verification rate.
  • Corrective-action implementation effectiveness.
  • Reduction in the recurrence rate of failures.
  • Internal and external customer satisfaction with failure-analysis deliverables.

Working Conditions

  • On-site role at a Texas manufacturing facility.
  • Work in electronics laboratory environments, including ESD-safe areas, microscopes, and soldering stations.
  • Occasional domestic or international travel to suppliers, customer sites, or corporate headquarters.
  • Normal working hours, with flexibility to support urgent failure-analysis cases and project deadlines.