Senior Electrical Failure Analysis Engineer

ZT Systems; Secaucus (NJ); On-site; USD 93,000 - 136,000; Full time

Benefits offered by this job

Competitive base salary

401(k) retirement savings plan

Tuition reimbursement

Paid time off

Wellbeing resources

Job summary

ZT Systems in the United States is seeking an Electrical Failure Analysis Engineer to lead RCA, failure characterization, and corrective actions across server, rack, cable, and electromechanical hardware. You will work closely with Metrology, Supplier Quality, Manufacturing, Design, and Reliability teams to identify root causes and prevent recurrence in high-volume manufacturing.

The role requires a Bachelor’s degree in Electrical Engineering or related field and 6+ years of experience with

Qualifications

• Bachelor’s degree in Electrical Engineering, Electronics Engineering, Physics, or related field.
• 6+ years of experience in Electrical Failure Analysis, Hardware Quality Engineering, Reliability Engineering, Manufacturing Quality, or related disciplines.
• Strong troubleshooting experience with electrical and electronic systems.
• Hands-on experience performing root cause investigations in manufacturing, quality, or reliability environments.
• Experience with structured problem-solving methodologies including 8D, DMAIC, Fishbone Analysis, 5-Why, and FMEA.

Responsibilities

• Lead electrical failure investigations involving connectors, cable assemblies, wire harnesses, power distribution systems, CB assemblies, and electromechanical components.
• Perform root cause analysis of electrical defects including opens, shorts, intermittent connections, excessive resistance, insulation breakdown, and ESD-related failures.
• Develop and execute fault isolation plans using electrical test equipment and laboratory analysis techniques.
• Correlate electrical failure signatures with dimensional, mechanical, and metrology data to identify failure mechanisms and process drivers.
• Drive containment, corrective actions, and preventive actions through structured methodologies including 8D, DMAIC, and CAPA processes.
• Partner with Manufacturing, Supplier Quality, and Engineering teams to resolve electrical nonconformances and improve product reliability.
• Develop electrical test methods, inspection procedures, and validation protocols to support manufacturing and quality operations.
• Support qualification, reliability, and environmental testing activities including thermal cycling, vibration, HALT, and HASS investigations.
• Analyze failure trends, field return data, and manufacturing defects to identify recurring issues and improvement opportunities.
• Review engineering drawings, schematics, wiring diagrams, and specifications to support failure analysis activities.
• Generate detailed technical reports documenting failure mechanisms, root causes, test results, and corrective actions.
• Support supplier audits, supplier corrective actions, and component qualification activities related to electrical and cable assembly suppliers.

Skills

Electrical fault analysis

Troubleshooting

Root cause analysis

Structured problem solving

Education

Bachelor’s degree in Electrical/Electronics Engineering or related field

Tools

DMM

Oscilloscopes

LCR meters

Power supplies

Continuity testers

Insulation resistance test equipment

Job description

ZT Systems in the United States is seeking an Electrical Failure Analysis Engineer to lead RCA, failure characterization, and corrective actions across server, rack, cable, and electromechanical hardware. You will work closely with Metrology, Supplier Quality, Manufacturing, Design, and Reliability teams to identify root causes and prevent recurrence in high-volume manufacturing.

The role requires a Bachelor’s degree in Electrical Engineering or related field and 6+ years of experience with