Zealogics.com

Global tech services with AI engineering

Hardware FMEA & Reliability Engineer

Hardware Validation & TestingConfirmed live in the last 24 hours

Full-timeSan Jose, CA, USA$50 - $60 /hrIn-person

About the Job

Requirements

A Bachelor's or Master's degree in Electrical Engineering, Electronics Engineering, Mechanical Engineering, Reliability Engineering, or a related field.
At least 5 years of experience in hardware development, reliability engineering, or product qualification.
Strong knowledge of Design Failure Mode and Effects Analysis (DFMEA), Process Failure Mode and Effects Analysis (PFMEA), Fault Tree Analysis (FTA), and risk management methodologies.
Experience with electronic assemblies, printed circuit board assemblies (PCBAs), power electronics, electromechanical systems, and hardware qualification testing.
Familiarity with reliability standards such as IEC, JEDEC, Telcordia, MIL-HDBK-217, and IPC standards.
Experience with statistical analysis, Weibull analysis, and reliability modeling.
Strong problem-solving, root-cause analysis, and technical documentation skills.

Responsibilities

Lead and facilitate Design Failure Mode and Effects Analysis (DFMEA) and Process Failure Mode and Effects Analysis (PFMEA) activities for hardware products.
Identify potential failure modes, root causes, and failure mechanisms across electrical, electronic, mechanical, and system-level designs.
Evaluate severity, occurrence, and detection ratings and develop risk mitigation plans.
Maintain and update FMEA documentation throughout the product lifecycle.
Track corrective and preventive actions resulting from FMEA reviews.
Support design reviews and ensure identified risks are addressed before product release.
Develop reliability requirements, reliability growth plans, and qualification test strategies.
Perform reliability predictions and analyses using industry standards such as MIL-HDBK-217, Telcordia SR-332, IEC, or equivalent methodologies.
Conduct Failure Analysis (FA), Root Cause Analysis (RCA), and corrective action implementation.
Analyze field returns, reliability data, and failure trends to improve product robustness.
Establish reliability metrics including MTBF, MTTF, FIT rates, and failure distributions.
Define and execute hardware reliability and environmental qualification test plans.
Coordinate and oversee temperature cycling, thermal shock, High Temperature Operating Life (HTOL), burn-in testing, Highly Accelerated Life Testing (HALT), Highly Accelerated Stress Screening (HASS), vibration testing, mechanical shock testing, humidity testing, salt fog and corrosion testing, power cycling, electrical overstress testing, EMC/EMI reliability verification, and safety and regulatory compliance testing.
Analyze test results and recommend design improvements based on findings.
Generate qualification reports and reliability assessment documentation.
Work closely with hardware design, PCB design, mechanical engineering, manufacturing, quality, and supplier teams.
Participate in design verification and validation activities.
Support supplier qualification and component reliability assessments.
Drive reliability best practices and lessons learned across engineering teams.

Desired Qualifications

Experience with high-voltage systems, industrial equipment, semiconductor equipment, or complex electromechanical products.
Knowledge of accelerated life testing methodologies and reliability growth modeling.
Six Sigma, ASQ Reliability Engineer, or equivalent certification.
Experience with reliability tools such as ReliaSoft, Windchill Quality Solutions, Minitab, JMP, or equivalent.

Job Summary
We are seeking a highly motivated Hardware FMEA & Reliability Engineer to drive product reliability and risk assessment activities throughout the product development lifecycle. The candidate will be responsible for conducting Design FMEA (DFMEA), Process FMEA (PFMEA), reliability analysis, and qualification testing for electronic, electrical, and electromechanical hardware systems. The role requires close collaboration with design, manufacturing, quality, and supplier teams to ensure robust, reliable, and high-quality products.
Key Responsibilities
FMEA & Risk Analysis

Lead and facilitate Design Failure Mode and Effects Analysis (DFMEA) and Process Failure Mode and Effects Analysis (PFMEA) activities for hardware products.
Identify potential failure modes, root causes, and failure mechanisms across electrical, electronic, mechanical, and system-level designs.
Evaluate severity, occurrence, and detection ratings and develop risk mitigation plans.
Maintain and update FMEA documentation throughout the product lifecycle.
Track corrective and preventive actions resulting from FMEA reviews.
Support design reviews and ensure identified risks are addressed before product release.

Reliability Engineering

Develop reliability requirements, reliability growth plans, and qualification test strategies.
Perform reliability predictions and analyses using industry standards such as MIL-HDBK-217, Telcordia SR-332, IEC, or equivalent methodologies.
Conduct Failure Analysis (FA), Root Cause Analysis (RCA), and corrective action implementation.
Analyze field returns, reliability data, and failure trends to improve product robustness.
Establish reliability metrics including MTBF, MTTF, FIT rates, and failure distributions.

Reliability Testing & Qualification

Define and execute hardware reliability and environmental qualification test plans.
Coordinate and oversee testing including:
- Temperature Cycling
- Thermal Shock
- High Temperature Operating Life (HTOL)
- Burn-In Testing
- Highly Accelerated Life Testing (HALT)
- Highly Accelerated Stress Screening (HASS)
- Vibration Testing
- Mechanical Shock Testing
- Humidity Testing
- Salt Fog / Corrosion Testing
- Power Cycling
- Electrical Overstress Testing
- EMC/EMI Reliability Verification
- Safety and Regulatory Compliance Testing
Analyze test results and recommend design improvements based on findings.
Generate qualification reports and reliability assessment documentation.

Cross-Functional Collaboration

Work closely with hardware design, PCB design, mechanical engineering, manufacturing, quality, and supplier teams.
Participate in design verification and validation activities.
Support supplier qualification and component reliability assessments.
Drive reliability best practices and lessons learned across engineering teams.

Required Qualifications

Bachelor's or Master's degree in Electrical Engineering, Electronics Engineering, Mechanical Engineering, Reliability Engineering, or related field.
5+ years of experience in hardware development, reliability engineering, or product qualification.
Strong knowledge of DFMEA, PFMEA, FTA (Fault Tree Analysis), and risk management methodologies.
Experience with electronic assemblies, PCBAs, power electronics, electromechanical systems, and hardware qualification testing.
Familiarity with reliability standards such as IEC, JEDEC, Telcordia, MIL-HDBK-217, and IPC standards.
Experience with statistical analysis, Weibull analysis, and reliability modeling.
Strong problem-solving, root-cause analysis, and technical documentation skills.

Preferred Qualifications

Experience with high-voltage systems, industrial equipment, semiconductor equipment, or complex electromechanical products.
Knowledge of accelerated life testing methodologies and reliability growth modeling.
Six Sigma, ASQ Reliability Engineer, or equivalent certification.
Experience with reliability tools such as ReliaSoft, Windchill Quality Solutions, Minitab, JMP, or equivalent.

About the Company

Zealogics.com

Global tech services with AI engineering

Zealogics provides enterprise and industrial AI solutions, engineering services, and global staffing. It uses the ZeaIQ AI Foundry to orchestrate multiple AI models in a secure environment for building agentic workflows, generative AI apps, defect detection, and predictive maintenance. The company distinguishes itself with a three-pillar model (Enterprise AI, Engineering Services, Global Staffing), a governance-enabled platform, and a focus on industries like semiconductor and manufacturing, backed by CMMI Level 3 and ISO 27001 certifications. Its goal is to deliver tailored technology solutions and skilled personnel that help clients solve complex problems and accelerate digital transformation.

Company size: 201-500
Company stage: Not listed
Total funding: Not listed
Headquarters: Branchburg, NJ
Founded: 2012

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