Failure Analysis Engineer

Cephas Consultancy Services Private Limited; Fort Worth (TX); On-site; USD 90,000 - 130,000; Full time

Job summary

Cephas Consultancy Services Private Limited in Fort Worth, Texas, is seeking a Failure Analysis Engineer to investigate and identify root causes of failures in electronic assemblies and server hardware. You will use advanced diagnostic tools and data-driven methods to drive product reliability improvements and CAPAs.

The role involves cross-functional collaboration with manufacturing, R&D, and quality teams, documentation of detailed FA reports, and support for supplier validation and process

Qualifications

• Bachelor’s degree in Electrical Engineering, Materials Science, Mechanical Engineering, or related field required.
• Master’s degree or equivalent experience in Reliability Engineering, Failure Analysis, or Quality Engineering preferred.
• 3–5 years of experience in failure analysis or reliability engineering within electronics, semiconductor, or high-tech manufacturing industries.
• Experience with AI server systems, GPU boards, or data center hardware is a plus.

Responsibilities

• Failure Analysis and Root Cause Investigation (50%).
• Perform electrical, mechanical, and thermal failure analysis on defective units from production, field returns (RMA), and reliability testing.
• Utilize analytical tools such as oscilloscopes, X-ray, SEM/EDS, decapsulation, and cross-sectioning for detailed investigation.
• Identify failure modes, document analysis results, and establish root cause and contributing factors.
• Correlate failures with design, process, and material data to support engineering improvements.
• Data Collection and Reporting (20%).
• Maintain detailed FA reports, including findings, corrective actions, and risk assessments.
• Present analysis summaries to internal engineering, manufacturing, and customer teams.
• Compile trend data on recurring failure modes and propose mitigation actions.
• Track metrics on failure rates, mean time between failure (MTBF), and reliability indicators.
• Cross-Functional Collaboration (15%).
• Partner with manufacturing, R&D, and quality engineering teams to drive corrective and preventive actions (CAPA).
• Support supplier quality teams in component failure validation and incoming inspection processes.
• Coordinate with customer support and warranty analysis teams on field failure investigations.
• Process and Product Improvement (10%).
• Participate in Design for Manufacturability (DFM) and Design for Reliability (DfR) reviews.
• Recommend design or process modifications to reduce defect rates and improve overall product robustness.
• Contribute to process control documentation and SOPs.
• Compliance and Safety (5%).
• Ensure all FA activities comply with ESD, ISO, and environmental standards (e.g., RoHS, REACH).
• Maintain lab equipment calibration and safe operating practices.

Skills

Python

JMP

Minitab

Excel

Education

Bachelor’s degree in Electrical Engineering, Materials Science, Mechanical Engineering, or related field

Master’s degree or equivalent experience in Reliability Engineering, Failure Analysis, or Quality Engineering preferred

Tools

Oscilloscope

DMM

Logic Analyzer

X-ray

SEM/EDS

FIB

Job description

Failure Analysis Engineer

Cephas Consultancy Services Private Limited Fort Worth Alliance, Texas, United States

About this position

Job Id :CLI-45654-5

Job Type: Direct hire

Position Summary

The Failure Analysis Engineer (FAE) is responsible for investigating, analyzing, and identifying root causes of failures in electronic assemblies, systems, and components used in high-performance computing, server, and AI-related hardware products. This role supports continuous improvement and product reliability initiatives through data-driven analysis, cross-functional collaboration, and corrective action implementation. The FAE will leverage advanced diagnostic tools and methods to enhance product quality, manufacturing yields, and customer satisfaction.

Supervisory Responsibilities

• May oversee FA Technicians and provide technical guidance and training.
• Coordinates project assignments and ensures timely completion of analysis reports.

Key Responsibilities

• Failure Analysis and Root Cause Investigation (50%)
• Perform electrical, mechanical, and thermal failure analysis on defective units from production, field returns (RMA), and reliability testing.
• Utilize analytical tools such as oscilloscopes, X-ray, SEM/EDS, decapsulation, and cross-sectioning for detailed investigation.
• Identify failure modes, document analysis results, and establish root cause and contributing factors.
• Correlate failures with design, process, and material data to support engineering improvements.

Data Collection and Reporting (20%)

• Maintain detailed FA reports, including findings, corrective actions, and risk assessments.
• Present analysis summaries to internal engineering, manufacturing, and customer teams.
• Compile trend data on recurring failure modes and propose mitigation actions.
• Track metrics on failure rates, mean time between failure (MTBF), and reliability indicators.

Cross-Functional Collaboration (15%)

• Partner with manufacturing, R&D, and quality engineering teams to drive corrective and preventive actions (CAPA).
• Support supplier quality teams in component failure validation and incoming inspection processes.
• Coordinate with customer support and warranty analysis teams on field failure investigations.

Process and Product Improvement (10%)

• Participate in Design for Manufacturability (DFM) and Design for Reliability (DfR) reviews.
• Recommend design or process modifications to reduce defect rates and improve overall product robustness.
• Contribute to process control documentation and standard operating procedures (SOPs).

Compliance and Safety (5%)

• Ensure all FA activities comply with ESD, ISO, and environmental standards (e.g., RoHS, REACH).
• Maintain lab equipment calibration and safe operating practices.

Qualifications

• Bachelor’s degree in Electrical Engineering, Materials Science, Mechanical Engineering, or related field required.
• Master’s degree or equivalent experience in Reliability Engineering, Failure Analysis, or Quality Engineering preferred.
• 3–5 years of experience in failure analysis or reliability engineering within electronics, semiconductor, or high-tech manufacturing industries.
• Experience with AI server systems, GPU boards, or data center hardware is a plus.

Technical Skills

• Proficiency with diagnostic equipment (oscilloscope, DMM, logic analyzer, X-ray, SEM, FIB, etc.)
• Knowledge of SMT manufacturing, solder joint analysis, and IPC standards.
• Familiarity with reliability testing (HALT, HASS, thermal cycling, vibration testing).
• Experience with data analysis tools (Python, JMP, Minitab, Excel).
• Ability to interpret schematics, layout drawings, and bill of materials (BOM).

Core Competencies

Analytical Thinking: Strong ability to dissect complex problems and identify root causes.

Technical Expertise: Deep understanding of electrical/electronic systems, PCB design, and semiconductor behavior.

Collaboration: Works effectively with multidisciplinary teams to solve technical challenges.

Communication: Ability to write clear, data-supported reports and present findings to technical and non-technical audiences.

Continuous Improvement: Passion for enhancing product reliability and manufacturing efficiency

Performance Indicators (KPI’s)

• Failure Analysis Turnaround Time (TAT)
• Root Cause Accuracy and Verification Rate
• Corrective Action Implementation Effectiveness
• Reduction in Recurrence Rate of Failures
• Customer Satisfaction (internal/external) with FA deliverables

Working Conditions

• On-site role at TX manufacturing facility.
• Exposure to electronics lab environments (ESD-safe areas, microscopes, soldering stations).
• Occasional travel to suppliers, customer sites, or corporate headquarters (domestic/international).
• Normal working hours with flexibility to support urgent FA cases and project deadlines.