Sustaining Reliability Engineer, Low Voltage Systems

About the role

We are looking for a Sustaining Reliability Engineer specializing in low-voltage (LV) electronics with a background in LV electronics modules and components. In this role, you will be at the forefront of our commitment to quality and reliability, executing responsibilities that directly impact our products' performance and customer satisfaction. You will identify risks and design mitigation strategies associated with manufacturing, from mass production through customer delivery. This role also involves using data and light analytics to detect and anticipate failures before they reach the field.

You will work with cross-functional teams and management, oversee validation testing, and convey results to all involved teams. A key part of the role is transitioning from New Product Introduction (NPI) to mass production while enhancing technology and scaling partnerships by cultivating and validating capable suppliers. You will develop and implement targeted validation plans for internal and external teams to detect reliability issues early during mass production. Additionally, you will assess manufacturing changes, develop test plans, and oversee root cause analysis for test failures. A passion for engineering transformative products and a self-motivated drive to push boundaries are essential.

Responsibilities

• Mitigate manufacturing risks and ensure product reliability during scaling, ramping, and high-volume production across global factories.
• Oversee production validation, early-life reliability monitoring, supplier qualification, and smooth NPI-to-mass production transitions.
• Apply expertise in reliability methods and low-voltage electronics to develop accelerated test plans for sustaining activities, including burn-in, ESS, ORT, and reliability growth demonstration.
• Generate validation test plans for manufacturing, process, or supplier changes (internal/external) and drive root cause corrective actions.
• Collaborate with quality, service, supplier, and design teams to conduct failure analysis and resolve testing/field failures; cascade reliability risks from design DFMEA into process PFMEA and control plans.
• Analyze field usage, environmental conditions, and reliability metrics to optimize test methods and requirements for ongoing production.
• Provide reliability guidelines, apply lessons learned, and use statistical methods to enable continuous improvements in manufacturing and early-life performance.
• Work closely with Field Reliability Teams to identify and drive mitigation for field excursions related to manufacturing deviations, maintaining a closed loop with NPI reliability teams.
• Pull together vehicle fault signals and environmental stress data (e.g., temperature, memory usage) and use light analysis to surface fleet risk and anticipate low-voltage failures.
• Maintain stakeholder-facing dashboards combining insights with Jira issues and reliability test results (validation, ESS, ORT), and use AI/LLM tools to speed up fault diagnosis and root cause analysis.

Requirements

• Degree in Mechanical Engineering, Electrical Engineering, Materials Engineering, Acoustics, or equivalent experience.
• 5+ years of experience with low-voltage electronic components/systems and laboratory testing (including relevant internships or academic lab work).
• Understanding of manufacturing processes for electronic components.
• Experience with burn-in testing, Environmental Stress Screening (ESS), and Ongoing Reliability Testing (ORT).
• Understanding of highly accelerated testing methods and governing equations for acceleration models (e.g., Arrhenius, Coffin-Manson, inverse power law), and reliability growth modeling.
• Experience developing reliability guidelines and innovative testing approaches for sustaining production.
• Working knowledge of reliability statistics, including Weibull analysis, and tools like JMP, Minitab, ReliaSoft, or MATLAB.
• Working knowledge of failure analysis techniques, such as optical microscopy, SEM, CSAM, X-ray, cross-sectioning, and EDX, and root cause analysis methods such as fault tree analysis.
• Proven ability to stay engaged, proactive, and positive in challenging situations.
• Working knowledge of SQL and Python for data analysis, and comfort using dashboard/visualization tools to share results with stakeholders.

Benefits

• Competitive pay and benefits starting on day 1 of hire.
• Medical plans with $0 payroll deduction options.
• Family-building, fertility, adoption, and surrogacy benefits.
• Dental and vision plans, including orthodontic coverage, with $0 paycheck contribution options.
• Company-paid Health Savings Account (HSA) contribution when enrolled in the High-Deductible medical plan.
• Healthcare and Dependent Care Flexible Spending Accounts (FSA).
• 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits.
• Company-paid Basic Life and AD&D insurance.
• Short-term and long-term disability insurance (90-day waiting period).
• Employee Assistance Program.
• Sick and vacation time (flex time for salary positions, accrued hours for hourly positions), and paid holidays.
• Back-up childcare and parenting support resources.
• Voluntary benefits, including critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance.
• Weight loss and tobacco cessation programs.
• Tesla Babies program.
• Commuter benefits.
• Employee discounts and perks program.

Pay

Expected compensation ranges from $91,600 to $316,800 annual salary, plus cash and stock awards and benefits. Pay may vary based on market location, job-related knowledge, skills, and experience.