Failure Analysis Engineer

Job Title

Failure Analysis Engineer

Role Summary

Perform root-cause failure analysis on electrical and mechanical components, sub-components and systems. Verify analog and digital performance, identify defect mechanisms, and recommend corrective actions to improve product reliability and manufacturing yield.

Work with process development, quality, production and suppliers to resolve failures, implement improvements, and support returns and reliability testing.

Experience Level

Mid-level (no specific years-of-experience stated).

Responsibilities

Key duties include laboratory analysis, data-driven problem solving, and cross-functional support to reduce failures and production losses.

• Perform electrical and mechanical failure analysis on returned products and production samples.
• Use structured root-cause methods (8D, 5 Whys, Ishikawa, FMEA) to investigate failures and document findings.
• Operate and maintain failure analysis tools such as SEM, X-ray and spectroscopy.
• Conduct process capability studies (Cp, Cpk), reliability testing and statistical analysis of failures.
• Develop and improve failure analysis methods, procedures and test equipment.
• Collaborate with process development, quality, production and suppliers to implement corrective actions.
• Maintain daily productivity reports and update process documentation and engineering drawings as required.
• Present technical findings to internal teams and external stakeholders.

Requirements

Must-have technical skills and workplace capabilities. Education requirements summarized separately below.

• Experience with failure analysis tools and techniques (SEM, X-ray, spectroscopy).
• Knowledge of materials science, mechanical properties and electrical connections (high voltage/current/resistance).
• Experience with data analysis and statistical tools (e.g. Minitab, MATLAB) and statistical process control (SPC), DOE.
• Ability to perform and interpret process capability (Cp/Cpk) and reliability test results.
• Ability to read blueprints, specifications and engineering change documents.
• Proficient with Microsoft Office (Excel, Word, PowerPoint, Outlook).
• Strong communication skills in Bulgarian and English (oral, written, presentation) and ability to work cross-functionally.
• Team player able to manage multiple tasks in a fast-paced environment.
• Nice-to-have: prior experience with supplier quality improvement and production process optimization.

Education Requirements

University degree required (e.g., Bachelor's) or equivalent relevant work experience. Relevant fields include engineering, materials science, physics or other technical disciplines; equivalent practical experience accepted.

About the Company

Company: Sensata Technologies

Headquarters: Attleboro, Massachusetts, United States

Sensata Technologies is a global industrial technology company focused on creating a safer, cleaner, and more efficient world. With a broad portfolio of mission-critical sensors and electrical protection components, Sensata addresses complex engineering demands across various markets including automotive, aerospace, and industrial. The company operates globally, employing over 18,000 people in 13 countries.