Job Specifications
Develop and implement a comprehensive reliability engineering strategy for hardware systems, with a focus on actuators, motor controllers, PCBAs, sensors, limbs, and end effectors.
Establish and maintain reliability metrics, goals, and test protocols for each product lifecycle stage, from design to production.
Collaborate closely with cross-functional teams (mechanical, electrical, firmware, and manufacturing) to integrate reliability principles into design and development processes.
Efficient Testing & Analysis: Ability to design reliability testing approaches that extract meaningful insights from small sample sizes, as large, statistically significant sample sizes (30+ units) are typically not available at our current stage of production. Must leverage statistical methods, engineering judgment, and accelerated testing techniques to drive data-informed decisions.
Apply component derating principles to ensure hardware components operate well within their rated limits, improving system reliability and longevity.
Analyze thermal, electrical, and mechanical stresses to identify potential failure points and recommend design adjustments.
Lead root cause analysis (RCA) for hardware failures, implementing corrective actions and preventative measures.
Develop and oversee reliability testing plans, including Highly Accelerated Life Testing (HALT), Highly Accelerated Stress Screening (HASS), vibration testing, and environmental stress testing.
Analyze field data, prototype testing results, and production feedback to identify trends and drive improvements.
Drive Design for Reliability (DfR) methodologies, including FMEA, DFMEA, stress analysis, and reliability growth modeling.
Partner with suppliers to verify the reliability and quality of sourced components, ensuring alignment with design and reliability standards.
Identify and implement design and process improvements to enhance product reliability, reduce failure rates, and improve durability.
Contribute to the development of reliability standards, documentation, and best practices to guide future hardware development.
Mentor and coach junior engineers, fostering a strong culture of reliability across the organization.
SKILLS AND REQUIREMENTS:
Extensive experience with reliability engineering principles, including component derating, FMEA/DFMEA, and Coffin-Manson analysis for fatigue prediction.
Proficiency in reliability testing methods such as HALT, HASS, vibration, and thermal cycling.
Strong understanding of mechanical systems, electronic components (PCBAs, motor controllers), sensors, and materials science.
Exceptional problem-solving and analytical skills, with a focus on data-driven decision-making.
Excellent communication and collaboration abilities, capable of working with cross-disciplinary teams and suppliers.
Proven ability to lead RCA efforts, implement corrective actions, and drive reliability improvements.
About the Company
Insight Global is an international professional services and staffing company specializing in delivering talent and technical solutions to Fortune 1000 companies across the IT, Non-IT, Healthcare, and Engineering industries. Fueled by staffing and talent experts, Evergreen, our professional services brand, brings technical advisors and culture consultants to help customers tackle their biggest challenges. With over 70 locations across North America, Europe, and Asia, and global staffing capabilities in 50+ countries, our tea...
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