Engineer Sr, Reliability

Dormont Manufacturing Co; Edison (NJ); On-site; USD 90,000 - 120,000; Full time

Job summary

Dormont Manufacturing Co is looking for a Sr. Reliability Engineer in Edison, New Jersey. This role focuses on supporting system reliability by developing failure models and defining test plans for battery management systems. The ideal candidate should have a Bachelor's in Electrical Engineering and 8 years of relevant experience.

The position requires expertise in reliability modeling, environmental testing, and root cause analysis, ensuring consistent product quality throughout production.

Qualifications

• 8 years of experience in systems engineering, reliability engineering, or related.

Responsibilities

• Lead reliability objectives for battery storage hardware.
• Develop long-term reliability test plans for all BMS circuit boards.
• Estimate annual failure DPPM using SR‑332 standards.
• Assess expected field use conditions.
• Identify components with potential wear-out mechanisms.
• Determine acceleration factors and test durations.
• Detect wear out failure modes during testing.
• Create HALT plans to uncover early-life failure mechanisms.
• Develop HASS plans to evaluate ongoing production quality.
• Participate in recurring reliability reviews.
• Provide guidance on reliability considerations.

Skills

Electronic component reliability

Reliability modeling tools (Relyence, RelCalc)

Environmental stress testing

Degradation mechanisms in electronic components

Root cause analysis

Education

Bachelor's degree in electrical engineering

Job description

Job Summary:

The Sr. Reliability Engineer will be responsible for supporting overall system reliability by developing the electronic-based failure bathtub curve, modeling long-term reliability, and defining accelerated test plans for battery management systems (BMS). The engineer will work closely with hardware, systems, and software teams to analyze failure modes, validate reliability assumptions, and drive corrective actions.

Job Responsibilities:

• Lead reliability objectives for battery storage hardware, including PCBAs and electromechanical assemblies
• Develop long-term reliability test plans for all BMS circuit boards, including thermal cycling, damp heat, and other environmental stresses aligned with warranty requirements
• Estimate annual failure DPPM (AFR%) using SR‑332 standards and reliability modeling tools
• Assess expected field use conditions including power‑on hours (POH), temperature exposure, and duty cycle
• Identify components with potential wear‑out mechanisms and develop degradation or failure‑rate models as needed
• Determine acceleration factors and test durations based on agreed upon field use assumptions
• Detect wear out failure modes during testing, coordinate root cause investigations, and recommend corrective or preventive actions
• Create HALT (Accelerated Life Test) plans to uncover early‑life and latent failure mechanisms and assess relevance to field conditions
• Develop HASS (Highly Accelerated Stress Screening) plans to evaluate ongoing production product quality
• Participate in recurring reliability reviews with engineering teams to track progress, risks, and timelines
• Provide guidance on system level and software related reliability considerations, including interactions between hardware, firmware, and operational conditions
• Support broader reliability initiatives within the battery storage platform as needed

Education/Experience

• Bachelor’s degree in electrical engineering required
• 8 years of experience in systems engineering, reliability engineering, or related

Skills/Abilities:

• Experience with electronic component reliability, SR 332 modeling, and AFR/DPPM estimation
• Proficiency with reliability modeling tools such as Relyence, RelCalc, or similar
• Strong understanding of environmental stress testing (thermal cycling, humidity, HALT, etc.)
• Familiarity with degradation mechanisms in electronic components and PCB assemblies
• Experience conducting root cause analysis and developing corrective actions for wear out failures