US - Wisconsin - Waukesha
November 17, 2024
Job Title: Senior Electrical Reliability and Failure Analysis Engineer
Company: Generac Power Systems
Location: Waukesha, WI
Position Summary:
Generac Power Systems is looking for a highly skilled Senior Engineer in Electrical Reliability and Failure Analysis to enhance the reliability and robustness of electronic components within our Energy Technology product line. This role involves in-depth failure analysis, qualification testing, and reliability assessments for components, ensuring they meet performance expectations and withstand real-world applications. The successful candidate will lead technical investigations into component failure mechanisms and support design improvements, collaborating closely with a diverse engineering team spread across North America.
Key Responsibilities:
Advanced Failure Analysis: Conduct detailed failure analyses at the component level using methodologies such as X-ray inspection, cross-sectioning, microscopy, and other advanced techniques.
Component Qualification and Validation: Oversee the qualification and validation process for electronic and electromechanical components, aligning them with application-specific reliability and durability standards.
Root Cause Analysis: Develop and implement methodologies to diagnose failure mechanisms, leading root cause investigations and producing comprehensive findings.
Post-Test Evaluation: Analyze and document the performance of components post-testing, providing actionable insights for design and process improvements.
Test Coordination and Support: Partner with engineering teams to establish system-level test procedures, acquire resources, manage test equipment, and troubleshoot complex issues as they arise.
Collaboration with Stakeholders: Work closely with manufacturing partners and other engineering stakeholders to enhance product design, reliability, and manufacturability, particularly for high-volume production environments.
Supplier Partnership: Coordinate with electronic component suppliers to identify and evaluate potential failure modes, ensuring components meet required standards.
Defect Analysis and Component Quality Assessment: Assess component quality, performing defect analyses to support quality control and ongoing product improvement.
External Lab Coordination: Manage relationships with external failure analysis labs, scoping and interpreting testing methodologies to inform component improvements.
Design for Reliability (DFR): Develop and implement component qualification matrices and guidelines, incorporating DFR principles to enhance product robustness and reliability.
Troubleshooting and Problem-Solving: Lead analytical troubleshooting sessions to address operational issues, set performance goals, and drive continual improvement.
Reporting: Compile formal reports on failure analysis findings, presenting data and conclusions to support informed decision-making across engineering and quality teams.
Required Qualifications:
Bachelor's Degree in Electrical Engineering or related field.
Minimum of 5 years' experience in electronic component application, validation, and failure analysis, with preference for experience in residential/commercial products.
Proficiency in physics-based failure analysis methodologies and the use of internal/external FA tools.
Preferred Qualifications:
Background in power electronics and/or power converters.
Experience with clean energy technologies such as solar or energy storage systems.
Proficiency in Altium or other PCB schematic capture and layout software.
Familiarity with analytical tools and techniques, including cross-sectioning, radiographic examination, microscopy, and bench testing.
Demonstrated experience in processing data and information to determine failure causes.
Knowledge of corrective and preventative actions for quality improvement.
Core Skills and Abilities:
Technical Expertise: Solid grounding in electrical engineering theory and failure mode analysis, with a thorough understanding of electronic and electromechanical components.
Component Validation: Proficient in developing and implementing component qualification plans, with knowledge of PCB layout best practices.
Manufacturing Knowledge: Experience with large-scale manufacturing, including mixed surface mount/through-hole PCBs and electromechanical assembly.
Attention to Detail and Problem-Solving: Keen attention to detail and an analytical mindset, with a passion for addressing complex engineering challenges.
Adaptability and Ambiguity Management: Ability to make progress in uncertain situations, finding solutions with limited information.
Organizational Skills: Strong time management and organizational abilities, prioritizing tasks and managing information to meet goals effectively.
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