Reliability and Failure Analysis Engineer

Foxconn; Bengaluru; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Foxconn in Bengaluru, India, seeks an experienced Failure Analysis leader to drive RCA, CAPA, and preventive strategies across design, quality, and manufacturing teams. The role emphasizes leadership, cross-functional collaboration, and reporting to senior leadership with strong customer-facing engagement.

The successful candidate will apply advanced FA techniques, oversee root-cause investigations of field returns and line failures, and develop an FA capability roadmap including tools,

Qualifications

• 10-15 years of experience in electronics manufacturing or a related field.
• Strong understanding of corrective action, CAPA, lab testing, product testing, quality testing principles.
• Experience with root cause analysis techniques such as 7QC tools or Fishbone diagrams.

Responsibilities

• Lead and define Failure Analysis methodologies, workflows, and best practices across FA investigations.
• Oversee RCA for field returns, production line failures, and reliability test escapes.
• Apply advanced FA techniques (cross-sectioning, SEM/EDX, X-ray/CT, SAM, Thermal/EMI diagnostics).
• Drive CAPA actions and feedback loops to design and manufacturing teams.
• Deliver high-quality FA reports, dashboards, and presentations for leadership and stakeholders.

Skills

Leadership

Analytical thinking

Problem-solving

Communication

Tools

DMM

Oscilloscopes

Power Analyzers

Thermal Imaging

Spectrum Analyzers

FA lab equipment

Job description

Roles and Responsibilities :

• Leadership & Strategy

  - Work with the Failure Analysis team for MLB/PCB, providing technical direction, mentorship, and career development.
  - Define and implement FA methodologies, workflows, and best practices to improve accuracy and efficiency of investigations.
  - Partner with design, quality, manufacturing, and supplier engineering teams to establish robust preventive strategies and Design-for-Reliability (DfR) initiatives.
  - Develop long-term FA capability roadmap including investment in advanced tools, automation, and training.

  Failure Analysis & Root Cause Investigation

  - Oversee systematic root cause analysis (RCA) of field returns, production line failures, and reliability test escapes.
  - Apply advanced FA techniques including cross-sectioning, SEM/EDX, X-ray/CT analysis, Scanning Acoustic Microscopy (SAM), and Thermal/EMI diagnostics.
  - Establish strong correlation between electrical failures and material/structural analysis to pinpoint defect mechanisms.
  - Drive corrective and preventive actions (CAPA) ensuring feedback loops to design and manufacturing teams.

  Technical Expertise

  - Deep expertise in signal integrity, power integrity, high-speed interfaces (DDR, PCIe, USB, etc.), and PCB material behaviors.
  - Proficiency with FA tools: DMM, Oscilloscopes (DSO/MSO), Power Analyzers, Thermal Imaging, Spectrum Analyzers, and high-end FA lab equipment.
  - Strong background in reliability stress testing (thermal cycling, humidity, ESD, HAST, burn-in) and failure mechanism identification.

  Cross-Functional Collaboration & Customer Engagement

  - Act as the technical point of contact for customer escalations, ensuring transparency, clear communication, and timely resolution.
  - Work closely with R&D, NPI, and manufacturing engineering to implement design changes and process optimizations.
  - Interface with global teams, suppliers, and external labs for specialized FA studies.

  Reporting & Documentation

  - Deliver high-quality FA reports, dashboards, and presentations for executive leadership, customers, and regulatory bodies.
  - Track failure trends, prepare quarterly reliability reviews, and recommend improvement strategies.
  - Ensure compliance with ISO, IPC, JEDEC, and industry FA standards.

  -Strong leadership, decision-making, and project management skills.
  - Exceptional analytical thinking and problem-solving abilities.
  - Excellent written and verbal communication skills to interact with global teams and high-profile customers.

Job Requirements :

• 10-15 years of experience in electronics manufacturing or a related field.
• Strong understanding of corrective action, CAPA, lab testing, product testing, quality testing, reliability testing principles.
• Experience with root cause analysis techniques such as 7QC tools or Fishbone diagrams.
• Job Highlights - Work with a FA lab and engineering team.
  - Opportunity to define FA strategy and influence product design & reliability at scale.
  - High visibility role with direct impact on customer satisfaction, cost of quality, and product performance