Lead Electrical Engineer, Hardware Reliability (Starlink)

Responsibilities

• Lead and mentor a team of engineers and specialists focused on hardware reliability and field performance for the Starlink User Terminal Kit, including user terminals, Wi-Fi routers, power supplies, and cables.
• Allocate resources across new product qualification campaigns, production reliability priorities, and field hardware investigations to ensure appropriate technical coverage, timely execution, and rapid troubleshooting of failures.
• Partner closely with hardware design, software, manufacturing, and supply chain teams to proactively influence current and future designs and maximize reliability across the product lifecycle.
• Develop and execute reliability qualification strategies for new and existing products to maximize field life, minimize early-life failures, and demonstrate readiness for mass production.
• Design and execute environmental, mechanical, electrical, RF, and system-level reliability testing tailored to product architecture, use conditions, and identified failure mechanisms to qualify changes in high volume manufacturing.
• Automate reliability test execution, data analysis, and reporting using appropriate data visualization and engineering tools to improve speed, repeatability, and technical decision-making.
• Define and monitor ongoing reliability testing and monitoring strategies to assess manufacturing process health and identify long-term reliability risks driven by process, material, and component variability.
• Define and monitor critical hardware and performance field metrics, such as product return rates, to identify and investigate product reliability shortcomings.
• Oversee production quality activities including containments, material review board (MRB), defect processing, quality metrics, training, and applicable command media for factory compliance.
• Identify manufacturing inefficiencies that impact product reliability and drive process improvements that increase first-pass yield, improve quality, reduce scrap, and accelerate issue detection and resolution.
• Maintain applicable quality system and ISO 9001 requirements.
• Lead root cause investigations for qualification, production, and field failures; identify immediate and underlying failure mechanisms and drive corrective actions to reduce product and process risk.
• Perform telemetry and log analysis as well as hands-on debugging to drive to root cause and corrective action of failed phased-array, Wi-Fi, and power supply PCBAs in the field.

Technical Scope

• Manage or lead technical investigations with tight timelines concerning isolated or fleet-wide performance or hardware issues that affect Starlink customers.
• Investigations may stem from test, production or field findings.
• Develop and execute reliability qualification strategies for new and existing products to maximize field life, minimize early-life failures, and demonstrate readiness for mass production.
• Design and execute environmental, mechanical, electrical, RF, and system-level reliability testing tailored to product architecture, use conditions, and identified failure mechanisms to qualify changes in high volume manufacturing.
• Automate reliability test execution, data analysis, and reporting using appropriate data visualization and engineering tools to improve speed, repeatability, and technical decision-making.
• Define and monitor ongoing reliability testing and monitoring strategies to assess manufacturing process health and identify long-term reliability risks driven by process, material, and component variability.
• Define and monitor critical hardware and performance field metrics, such as product return rates, to identify and investigate product reliability shortcomings.
• Oversee production quality activities including containments, material review board (MRB), defect processing, quality metrics, training, and applicable command media for factory compliance.
• Identify manufacturing inefficiencies that impact product reliability and drive process improvements that increase first-pass yield, improve quality, reduce scrap, and accelerate issue detection and resolution.
• Maintain applicable quality system and ISO 9001 requirements.
• Lead root cause investigations for qualification, production, and field failures; identify immediate and underlying failure mechanisms and drive corrective actions to reduce product and process risk.
• Perform telemetry and log analysis as well as hands-on debugging to drive to root cause and corrective action of failed phased-array, Wi-Fi, and power supply PCBAs in the field.
• Understand Wi-Fi standards and how the Starlink network operates.

Qualifications

• Bachelor's degree in electrical engineering, mechanical engineering, materials engineering, manufacturing engineering, aerospace engineering, or another engineering discipline.
• 2+ years of experience executing complex engineering projects in design qualification, manufacturing, hardware reliability, reliability test, or a production environment.
• 1+ years of experience in a leadership position leading a team of 3+ engineers.

Preferred Skills And Experience

• Master’s degree in electrical, mechanical, materials, manufacturing, aerospace engineering, or a related engineering discipline.
• Experience developing and executing product qualification or hardware reliability strategies.
• Experience developing objective test, inspection, and acceptance criteria.
• Strong understanding of reliability engineering principles, failure mechanisms, root cause investigation, and risk-based engineering decision-making.
• Experience developing environmental, mechanical, electrical, RF, or system-level test methods.
• Experience with PCB, PCBA, electromechanical assemblies, and complex hardware systems.
• Demonstrated ability to investigate complex hardware failures and drive corrective actions to closure.
• Experience with high-volume manufacturing and transitioning hardware from development into mass production.
• Experience with automation of test execution, data analysis, or engineering reporting.
• Experience monitoring and aggregating hardware telemetry to identify key performance trends or anomalies.
• Demonstrated experience training, mentoring, and developing engineers.
• Demonstrated ability to organize, prioritize, assign, and track technical work and deliverables across multiple concurrent priorities.
• Demonstrated ability to influence cross-functional organizations through strong engineering rationale, business judgment, and data.
• Excellent written and verbal communication skills.