Sr NPI Reliability Engineer

Our Mission

At Palo Alto Networks®, we’re united by a shared mission—to protect our digital way of life. We thrive at the intersection of innovation and impact, solving real‑world problems with cutting‑edge technology and bold thinking. Here, everyone has a voice, and every idea counts.

Who We Are

We aim to be the cybersecurity partner of choice by trailblazing the path and shaping the future of our industry. Our values are Disruption, Collaboration, Execution, Integrity, and Inclusion. We weave AI into everything we do to augment the impact each individual can have. Most of our teams work from the office full‑time, with flexibility when needed, to support real‑time problem‑solving, stronger relationships, and precise outcomes.

Job Summary

Palo Alto Networks is seeking an experienced NPI Hardware Reliability Engineer to join the Technical Operations Hardware Quality Engineering organization. The role establishes and drives hardware reliability and quality processes throughout the New Product Introduction (NPI) lifecycle for next‑generation network security and firewall platforms, collaborating with Product Engineering, Quality, Manufacturing, Supplier Quality, Test Engineering, and Operations.

Key Responsibilities

• NPI Reliability & Quality
  • Own and execute the NPI hardware reliability strategy, milestones, and phase‑gate qualification plans from early development through production ramp.
  • Partner with Hardware Engineering to assess architecture, design changes, and BOMs for electrical, mechanical, thermal, and environmental risks.
  • Define and execute accelerated life, stress, and environmental test plans (thermal cycling, drop/vibe, HALT/ALT), setting sample sizes, conditions, and pass/fail criteria.
  • Analyze test data and trends to validate product readiness against reliability targets before commercial release.
• Failure Analysis & Corrective Action
  • Lead root‑cause investigations across NPI testing, pilot builds, and early production using structured methods (8D, FMEA, FTA, DOE, Weibull).
  • Collaborate with Design, Manufacturing, Supplier Quality, and CMs to implement, validate, and track closed‑loop corrective actions.
  • Feed field and post‑mortem learnings back into early NPI cycles to prevent recurring failure modes.
• Manufacturing & Supplier Reliability
  • Assess supplier and manufacturing reliability risks during EVT, DVT, and PVT builds, auditing critical processes, materials, and component qualifications.
  • Establish quality controls, test coverage, and containment protocols for critical hardware components and sub‑assemblies.
• Analytics & Cross‑Functional Leadership
  • Define NPI reliability metrics, statistical models, and dashboards to communicate risks and launch readiness to executive leadership.
  • Act as the Technical Operations SME for hardware reliability, partnering with cross‑functional engineering, program management, and external CM partners.
• Process & Framework Infrastructure
  • Build, standardize, and scale the company’s NPI Hardware Reliability framework, including templates, phase‑gate criteria, and lessons‑learned mechanisms across multiple hardware platforms.

Qualifications

• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Materials Engineering, Reliability Engineering, or a related technical field.
• 5+ years of experience in hardware reliability, product quality, NPI, manufacturing engineering, or a related discipline.
• Experience with reliability qualification and validation of complex electronic hardware.
• Strong understanding of hardware failure mechanisms and reliability engineering principles.
• Experience working with contract manufacturers and external suppliers.
• Experience with NPI processes and production ramp of complex electronic products.
• Strong analytical and problem‑solving skills.
• Experience with structured root‑cause and failure‑analysis methodologies.
• Ability to interpret engineering drawings, schematics, BOMs, specifications, and manufacturing documentation.
• Strong written and verbal communication skills.

Preferred Qualifications

• Master’s degree in Reliability Engineering, Electrical Engineering, Mechanical Engineering, or a related discipline.
• Experience with networking, server, datacenter, storage, telecommunications, or cybersecurity hardware.
• Experience qualifying high‑complexity systems containing PCBs, processors, memory, power supplies, thermal systems, fans, chassis, connectors, and high‑speed interfaces.
• Experience with HALT, HASS, accelerated life testing, Weibull analysis, reliability prediction, and statistical analysis.
• Experience with FMEA, Fault Tree Analysis, DOE, and reliability modeling.
• Experience with hardware quality systems and ISO 9001‑based processes.
• Experience using data analytics and visualization tools to monitor reliability and quality performance.
• Experience with RMA/field‑return analysis and incorporating field lessons into NPI.
• Experience leading cross‑functional technical projects without direct authority.

Compensation

The starting base salary range for this position is $108,200.00 – $174,900.00 per year, depending on qualifications, experience, and work location. Additional compensation may include restricted stock units and a bonus.