Senior Reliability Engineer - Hybrid

This opening is part of our September 2026 Defense Electronics Engineering Hiring Event. While we encourage all interested professionals to apply, this is a selection-based interview event for candidates whose skills and experience match our hiring needs. If selected, specific opportunities based on your interests and background will be discussed. Virtual interviews will be accommodated for non-local candidates.

About the role

We are seeking a motivated and detail-oriented Reliability Engineer to join our dynamic team. You will play a vital role in ensuring the reliability and performance of our systems, working alongside experienced engineers and contributing to continuous improvement. This role offers opportunities to expand your skill set and take on increasing responsibilities as you progress within the company.

Responsibilities

• Failure Analysis & FRACAS (Failure Reporting, Analysis, and Corrective Action System)
  • Analyze failed hardware and software components from production and field returns to determine root cause of failures and assist in developing corrective actions.
  • Collaborate with internal teams (Quality, Hardware Design, Manufacturing, Software Engineering) to gather information, facilitate investigations, and implement solutions.
  • Interface with suppliers/vendors to review their failure analysis findings, ensure alignment, and drive resolution of supplier-related issues.
  • Perform detailed failure analysis using techniques such as visual inspection, microscopy, component-level testing, data analysis, X-ray, or SEM.
  • Author clear, concise, and technically accurate customer-facing failure reports, including recommended corrective actions.
  • Maintain and update the FRACAS database with accurate failure data, analysis results, and corrective action tracking.
  • Review and interpret data from manufacturing process monitoring, environmental stress screening (ESS), and system testing to identify potential reliability concerns.
  • Collaborate with test teams to investigate failure modes, refine test procedures, and improve test coverage.
• Reliability Data Analysis & Prediction
  • Collect, analyze, and interpret reliability data from field failures, testing, and simulations to identify trends and potential areas for improvement.
  • Utilize statistical tools and techniques (Weibull analysis, MTBF/MTTR calculations, FMECA, Root Cause Analysis, hypothesis testing) to assess system reliability and predict future performance.
  • Develop and maintain reliability prediction models to assess design margins and optimize product life.
  • Perform Reliability Growth Analysis to track improvement over time.
  • Contribute to the development of reliability test plans and strategies.
• Maintainability & Testability Analysis
  • Perform Maintainability analysis, estimate Mean Time To Repair (MTTR), and identify opportunities to improve product serviceability.
  • Perform system-level testability analysis and demonstrate the effectiveness of diagnostic features.
  • Support the development and implementation of diagnostic procedures to facilitate efficient troubleshooting.
• Process Improvement & Quality Assurance
  • Identify opportunities to improve manufacturing processes, design practices, and quality control procedures to reduce failure rates and enhance product reliability.
  • Contribute to the development and implementation of corrective and preventative actions (CAPA).
  • Participate in Design for Reliability (DFR) and Design for Manufacturability (DFM) reviews.
  • Lead small-scale reliability improvement projects.
• Documentation & Reporting
  • Create and maintain detailed documentation of failure analysis results, test procedures, reliability data, and analysis reports.
  • Prepare and deliver presentations summarizing reliability findings for internal and external stakeholders (engineering teams, management, customers, vendors).

Requirements

• Bachelor’s degree in engineering (Electrical, Mechanical, Aerospace, Systems, or related field) with at least 4 years of experience (2 years with a Master’s degree).
• Strong analytical and problem-solving skills.
• Excellent written and verbal communication skills.
• Proficiency in Microsoft Office Suite (Excel, Word, PowerPoint).
• Ability to work independently and as part of a team.
• Ability to obtain and maintain a security clearance.
• Proven ability to lead cross-functional teams and reliability science initiatives, including failure analysis, proposal development, and program status management.

Preferred Skills

• Experience with failure analysis techniques (e.g., visual inspection, microscopy, X-ray, electrical testing).
• Familiarity with reliability standards (e.g., MIL-STD-883, MIL-STD-750, MIL-HDBK-217, MIL-STD-1629A, MIL-STD-454, MIL-STD-470, MIL-HDBK-472).
• Knowledge of statistical analysis tools (e.g., Minitab, JMP).
• Experience with FRACAS databases, Reliability Testing, Fault Tree Analysis (FTA), and Reliability/Maintainability Modeling including Availability.
• Experience with electronic circuits and components.
• Understanding of manufacturing processes.
• Experience with Python or other scripting languages for data analysis.

Pay

Full-Time Salary Range: $105,827 – $179,906. Individual salaries are determined by a variety of factors including business considerations, local market conditions, internal equity, and candidate qualifications such as skills, education, and experience.

Benefits

Regular employees scheduled to work 20+ hours per week are offered:

• Health, dental, and vision insurance.
• Health savings accounts.
• 401(k) savings plan.
• Disability coverage and life and accident insurance.
• Employee assistance program and legal plan.
• Paid time off, paid holidays, and other leave programs including paid parental, military, bereavement, and applicable federal and state sick leave.
• Employee recognition program with monetary or non-monetary awards.
• Other incentives based on position level and job specifics.
• Discounts on home, auto, and pet insurance.

About BAE Systems Electronic Systems

BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace, and security company delivering products and services for air, land, and naval forces, as well as advanced electronics, security, information technology solutions, and customer support services. Our mission is to improve the future and protect lives through breakthrough technology, superior products, and intelligence solutions.

Electronic Systems (ES) is the global innovator behind BAE Systems’ game-changing defense and commercial electronics. Our products and capabilities span from the depths of the ocean to the far reaches of space. With over 14,000 highly talented employees, we push the limits of what is possible to give our customers the edge and provide opportunities to change the world.