Failure Analysis Engineer Sr/Process Engineer Sr

Plexus Corp; Neenah (WI); On-site; USD 77,000 - 116,000; Full time

Job summary

Plexus Corp in Wisconsin is seeking a Failure Analysis Engineer Sr/Process Engineer Sr to provide technical expertise across the manufacturing process, optimize production for quality, and train teams. The role emphasizes collaboration, continuous improvement, and applying advanced analysis methods.

Responsibilities include root-cause investigations of failed components and PCBA's, hands-on lab work (SEM, X-ray, EDS, XRF), and leading FA workflows while coordinating with R&D, design, and quality

Qualifications

• Bachelor's Degree with 4+ years of related experience preferred.
• Strong analytical and statistical analysis skills; SPC software skills.
• Ability to develop working relationships with team members and customers.
• Lab tool/ test/measurement equipment experience preferred.

Responsibilities

• Communicate project technical subject matter with customers and internal teams.
• Demonstrate expertise across Plexus Manufacturing processes on projects.
• Work independently across multiple manufacturing phases without direct guidance.
• Perform root cause analysis on failed components and PCBA's.
• Operate lab equipment and tests (SEM, X-ray CT, EDS, XRF, IC).
• Develop and update failure analysis workflows and SOPs.
• Deliver detailed technical reports and FA presentations.
• Mentor junior engineers and technicians.
• Collaborate with R&D, design, quality, and manufacturing to feed FA insights into NPI.
• Maintain lab readiness and manage supplies and samples.

Skills

Communications

Manufacturing process

Root cause analysis

Lab equipment

Procedure development

Technical reporting

Mentorship

Cross-functional collaboration

Lab leadership

Education

Bachelor's Degree

Tools

SEM

2D/3D X-ray CT

EDS

XRF

Ion Chromatography

Job description

About us:

At Plexus, our vision is to help create the products that build a better world. Driven by a passion for excellence, we partner with leading Aerospace/Defense, Healthcare/Life Sciences and Industrial companies to design, manufacture and service some of the world's most transformative products, including advanced surgical systems, diagnostic instruments, healthcare imaging equipment, mission critical aerospace systems, and electric vehicle (EV) charging solutions. Visit Plexus.com to learn more about our unwavering commitment to our vision.

When we invest in our people, we invest in building a better world.

With a vision rooted in the wellbeing and inclusive engagement of our team members, our customers, their end users and our communities, people are the heart of what we do and who we are. It is our values that unite us and guide us in everything that we do, including how we operate, behave and interact to foster a workplace where every team member feels valued and empowered to contribute their best.

Our values include: Growing our People, Building Belonging, Innovating Responsibly, Delivering Excellence and Creating Customer Success.

As a team member, you will engage in impactful work through global collaboration and the use of emerging technologies, join an inclusive culture where every team member is valued and working toward a greater purpose, and be empowered to reach your full potential through various development programs designed to accelerate your growth.

Plexus offers a comprehensive benefits package designed to support team members' wellbeing, including medical, dental, and vision insurance, paid time off, retirement savings, and opportunities for professional development. We also prioritize work-life balance and offer a variety of perks to enhance the team member experience. For more information, visit our US benefits website at usbenefits.plexus.com. Our commitment to pay range transparency fosters an equitable workplace, where everyone can feel valued. The annual compensation range for this position is stated below. The salary offered within this range will be based upon the geographic location, work experience, education, licensure requirements and/or skill level. Salary Range:

$77,400.00 - $116,000.00

Purpose Statement:

The Failure Analysis Engineer Sr/Process Engineer Sr is responsible for providing technical expertise throughout the manufacturing process. This role involves offering guidance on best practices and equipment, optimizing production for efficiency and quality, training various teams, and supporting ongoing production activities.

Key Job Accountabilities:

• Demonstrates effective communications (teleconference, email, and in-person) through interaction with customers (internal and external) regarding project technical subject matter.


• Demonstrates expertise in the full Plexus Manufacturing process on small to mid size projects, as it applies to their role.


• Demonstrates the ability to work independently in multiple phases / processes of the Manufacturing Process, without direction from mentors or functional management, as it applies to their role.


• Root Cause Investigation -Execute advanced destructive and non-destructive failure analysis on failed components and PCBA's to determine exact root causes


• Lab & Equipment Operation -Manage and perform hands-on analysis using lab equipment/techniques such as SEM, 2D/3D uCT Xray, EDS, XRF, Ion Chromatography, C3, SIR,Micro-section,Dye & Pry, & De-Capsulation


• Procedure Development -Establish, update, and scale failure analysis workflows & standard operating procedures


• Technical Communication -Deliver clear, detailed technical reports and failure analysis presentations to internal stakeholders, management, and external customers


• Mentorship & Guidance -Provide technical guidance, training, and oversight to junior engineers & technicians


• Cross-Functional Collaboration -Partner closely with R&D, design, quality, and manufacturing engineering teams to feed FA insights back into new product development (NPI)


• Lab Leadership - Ensure the lab is \"tour ready\" at all times and that lab supplies and testing samples are stored in an organized and controlled manner, and stay current on industry trends, techniques, & standards relative to failure analysis

Education/Experience Qualifications:

• Bachelor's Degree with 4 or more years of related experience is preferred. An equivalent combination of education and/or experience will be considered.

Other Qualifications:

• Intermediate Computer Skills


• Intermediate Decision Making, Problem Solving Skills


• Intermediate Verbal and Written Communications Skills


• Strong Analytical and statistical analysis Skills; Statistical Process Control Software Skills


• Intermediate Cross-Discipline Development Knowledge


• Strong understand Structured Design


• Ability to develop good working relationships with team members and customers


• Lab tool/ test/measurement equipment experience preferred

This document does not represent a contract of employment and is not intended to capture every possible assignment the incumbent could be asked to perform.

We are pleased to provide reasonable accommodations to individuals with disabilities or special requirements. If you need an application accommodation, please contact us by email at [e-mail]. Please include your contact information and clearly describe how we can help you. This email is for accommodation requests only and cannot be used to inquire about the status of applications.

We are an Equal Opportunity Employer (EOE) and do not discriminate based on race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.

Some offers of employment are contingent upon successfully passing a drug screen and/or background check.