Staff Reliability Engineer (m/f/d)

BorgWarner; Viana do Castelo; Hybrid; EUR 55,000 - 75,000; Full time

Job summary

BorgWarner seeks a Staff Reliability Engineer to lead product reliability analyses across lifecycles, including DVP&R, warranty data, and field performance. You will build predictive models, strengthen reliability tools, and mentor teams in reliability methods.

You will collaborate with cross-functional teams, develop dashboards in Power BI, and drive data-driven decisions to improve product reliability and warranty forecasting across programs.

Qualifications

• Experience with reliability analysis tools and methodologies (Weibull++, Minitab, JMP).
• Knowledge of warranty processes, field performance analysis, and reliability prediction techniques.
• Experience with statistical analysis, predictive modeling, and warranty forecasting.
• Experience with Power BI, database management, and data visualization tools.
• Working knowledge of DFMEA, DfR, and structured problem-solving methodologies (8D, 5 Whys, RCA).
• Experience supporting senior management in a fast-paced, metrics-driven technical team.
• Ability to lead small global cross-functional investigations with strong communication.

Responsibilities

• Design Validation Plan & Report Support (DVP&R) activities, life predictions, and data analysis.
• Warranty analysis, data correlation, and root-cause investigations to drive improvements.
• Develop and maintain warranty analytics tools, databases, and Power BI dashboards.
• Provide training, coaching, and plant support on reliability methods and statistics.
• Prepare executive summaries and support leadership decisions with data-driven insights.

Skills

Reliability analysis

Weibull++

Minitab

JMP

Warranty analysis

Power BI

Data visualization

DFMEA

DfR

Root Cause Analysis

Education

Six Sigma Green Belt

Six Sigma Black Belt

Tools

Power BI

SharePoint

MATLAB

Weibull++

Minitab

JMP

Python

Job description

The Staff Reliability Engineer leads product reliability analysis and prediction throughout the product lifecycle. The position applies reliability methods to evaluate DVP&R results, warranty claims, field-performance data, failure modes analysis and risk evaluation. In collaboration with cross-functional team, the role ensures effective execution of reliability processes, drives continuous improvement of reliability tools, and strengthens the integration of reliability principles across the organization.

LI-Hybrid Key Responsibilities

Design Validation Plan & Report Support (DVP&R)

• Perform design life predictions and improve life test efficiency for new and existing programs.
• Analyze historical warranty and DVP&R data to assess product risks.
• Correlate design lifetime, validation/accelerated durability test results, and field data to validate customer required lifetime performance.

Warranty Analysis

• Conduct and quantify product specific warranty risk evaluations using statistical analysis.
• Analyze warranty claims and warranty returns root causes, to identify improvement opportunities and validate corrective actions.
• Correlate warranty performance and field data to improve reliability prediction accuracy and support design decisions.
• Support escalated field issue investigations with reliability assessments and structured data analysis.
• Identify emerging failure trends to enable early intervention.

Warranty Data Management

• Improve reliability prediction models, simulation methods, and durability test strategies through analysis of warranty, validation, and field-performance data.
• Develop and enhance warranty analytics tools, databases, and Power BI dashboards to support reliability assessments and business decisions.
• Ensure the integrity, quality, and effective use of warranty data to identify trends, assess risks, and improve prediction accuracy.
• Develop and maintain product and customer reliability databases to support warranty forecasting, reliability prediction models, and identification of trends across products and customers.

Training, Coaching and Plant Support

• Provide internal training and coaching on reliability methods and statistical tools.
• Support manufacturing plants with reliability assessments and structured problem-solving methodologies and best practices.
• Lead knowledge-sharing activities to promote lessons learned and the application of reliability best practices across the organization.
• Support customer meetings and technical discussions when required.
• Prepare executive-level summaries to support leadership decision-making.

CORE DELIVERABLES

• Reliability risk assessments and life prediction analyses supporting product development and production programs.
• Warranty and field-performance analyses identifying emerging failure trends and risks.
• Reliability prediction models and data-driven recommendations support design, validation, and business decisions.
• Product and customer reliability databases providing warranty forecasting, trend analysis, and predictive analytics.
• Reliability dashboards, reports, and analytical tools that improve visibility of warranty and field performance.
• Technical assessments and recommendations for critical field issues, customer escalations, and reliability risks.
• Training materials, coaching programs, and knowledge-sharing activities that strengthen organizational reliability capability.
• Executive-level summaries and presentations supporting leadership decision-making.

What we're looking for:

EDUCATION AND EXPERIENCE (Minimum Qualifications)

• Experience with reliability analysis tools and methodologies (e.g., Weibull++, Minitab, JMP).
• Knowledge of warranty processes, field performance analysis, and reliability prediction techniques.
• Experience with statistical analysis, predictive modeling, and warranty forecasting.
• Experience with Power BI, database management, and data visualization tools.
• Working knowledge of DFMEA, Design for Reliability (DfR), and structured problem-solving methodologies (8D, 5 Whys, Root Cause Analysis).
• Experience supporting senior management in a fast paced, metrics driven technical teams.
• Ability to lead small global, cross-functional teams during investigations with strong communication, negotiation, and consensus building skills.
• Demonstrated ability to generate innovative solutions and explore new analytical methods.

Education, Skills, Knowledge Requirements

• Hands-on experience with reliability analysis and Weibull tools (e.g., Weibull++, MATLAB, Minitab, JMP).
• Knowledge of warranty procedures and requirements.
• Experience using Six Sigma tools; Lean Green or Black Belt preferred.
• Working knowledge of DFMEA and problem-solving tools (8D, 5 Whys, Quality Alerts, Root Cause Analysis).
• Familiarity with Python programming.
• Experience with Power BI and SharePoint for data visualization and collaboration.

CORE COMPETENCIES

• Priority Setting
• Motivating Others
• Process Management
• Problem Solving
• Functional/Technical Skills
• Decision Quality
• Ethics and Values
• Customer Focus
• Drive for Results
• Business Acumen

What we believe

• Inclusion – We value diversity in people, ideas, and experiences.
• Integrity – We believe in transparency, authenticity, and depend on each other to deliver what we promise.
• Excellence – We contribute to our developments by seeking knowledge and sharing information.
• Responsibility – We care about our local communities and the global environment.
• Collaboration – We are one BorgWarner.

Safety

This position will adhere to Global Star Safety Program, including safety rules, practices and training as outlined in the BorgWarner PTC Safety Policy Manual, which includes the use of equipment, protective devices, or clothing that the employer requires. This individual will work in manners that stress the importance of preventing accidents and illnesses. He/she must take every precaution reasonable in the given circumstance for the protection of themselves and coworkers. In addition, he/she is responsible for reporting all injuries and/or possible dangerous situations, incidents, or occurrences to the immediate supervisor.

Equal Employment Opportunity

BorgWarner is an equal employment opportunity employer such that all qualified applicants will receive consideration for employment without regard to race, color, age, religion, sex, sexual orientation, gender identity/expression, national origin, disability or protected veteran status.

Join the Company

Join the company that is creating solutions that support a cleaner, more energy-efficient world. For more information about BorgWarner, please visit www.borgwarner.com

BorgWarner – Our Vision and Culture

BorgWarner is a global product leader in delivering innovative and sustainable mobility solutions. We are a company of innovators and independent thinkers that brings together talented employees, meaningful work and amazing technology in a unique environment. At BorgWarner we constantly work towards our vision of a clean and energy-efficient world.

Career Opportunities

We manage talent as seriously as we manage our businesses and encourage you to learn about our proud history, strong culture, technologies, and vision for the future. We offer positions locally and globally with over 90 locations in 19 countries. If this position energizes you and you feel you can help us achieve our mission and vision, you are invited to submit an application for consideration.

You may see the list of requirements and feel you do not meet all of them. However, remember that BorgWarner thinks differently. If your qualifications align with the majority of those outlined in this job description, we encourage you to apply and share your experience and skills with us.