Senior Failure Analysis Engineer

Mainspringenergy; Edison (CA); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

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Job summary

Mainspringenergy is seeking a Senior Failure Analysis Engineer with a strong electrical background to own electrical failure investigations across hardware platforms. You will apply structured problem-solving to identify failure mechanisms and drive CAPA programs to improve reliability.

You will work closely with Design, Manufacturing, Quality, Reliability and field teams to accelerate problem resolution, enhance test coverage, and build a robust knowledge base.

Qualifications

• Bachelor's degree in Electrical Engineering, Physics, or related technical discipline.
• 5-8+ years of direct experience in failure analysis, electrical troubleshooting, or reliability engineering.
• Deep expertise in system-level electrical interactions, EMC/EMI issues and environmental degradation.
• Proficiency with structured problem-solving methodologies (8D, Ishikawa diagrams, 5-Why).
• Strong verbal and written communication to construct FA reports and present data.
• Experience coaching or mentoring junior engineers or technicians.

Responsibilities

• Lead hands-on investigations of electrical enclosures and hardware across low- to high-voltage systems.
• Drive root cause analysis and translate findings into CAPA actions.
• Accelerate FA throughput by streamlining diagnostic workflows.
• Collaborate cross-functionally with design, manufacturing, quality, reliability, and field teams.
• Build a knowledge base documenting workflows, teardowns, and failure data.
• Coach and mentor less experienced engineers and technicians.

Skills

Structured problem-solving

Cross-functional collaboration

Technical communication

Mentoring

Hands-on lab work

Education

Bachelor's in Electrical Engineering

Bachelor's in Physics

Tools

EMC/EMI analysis

Failure analysis equipment

Job description

Our Linear Generator is a sophisticated system integrating a wide range of engineering disciplines, including thermodynamics, mechanical, electrical, software, and controls. To support our rapid transition into volume manufacturing we are actively expanding the scope and size of our Failure Analysis team.

We are looking for a highly motivated Senior Failure Analysis Engineer with a strong electrical engineering background to join us. In this role, you will own the investigation of electrical failures, scaling our FA throughput and translating physics-of-failure insights into hardware improvements. This is a high-visibility and high-impact role where your findings will help steer design iterations, prevent escapes, increase test coverage and help ensure the ultimate reliability of the fundamentally new class of power generation.

• Lead Hands-on Investigations: Perform deep-dive troubleshooting and debugging on a wide variety of electrical enclosures and hardware, ranging from low-voltage logic controllers to high-voltage power switching systems

• Drive Root Cause Analysis: Apply structured engineering and problem-solving methodologies to pinpoint mechanisms of failure, translating your findings into actionable containment, corrective, and preventive actions (CAPA)

• Accelerate FA Throughput: Streamline diagnostic workflows and optimization techniques to increase the pace of our failure analysis loop, ensuring rapid feedback for fast-moving product upgrade programs

• Collaborate Cross-Functionally: Work closely with Design Engineering, Manufacturing, Quality, Reliability, and field maintenance teams to clearly communicate data-driven FA findings and influence product improvements

• Build the Knowledge Base: Document diagnostic workflows, teardown procedures, and failure-mode data to build a resourceful knowledge base

• Coach and Mentor: Provide technical guidance, mentorship, and coaching to less experienced failure analysis engineers and technicians, raising the collective technical bar and impact of the team

• You thrive at the intersection of electrical hardware and physics. You love getting your hands on in the lab, tracing signals, and finding the needle in a haystack within complex electrical architectures

• You are fascinated by environmental and system interactions. The challenge of understanding how EMC/EMI issues, thermal cycling, moisture, and harsh operating environments interact with complex power electronics excites you

• You are a master of structured problem-solving. You don't rely on guesswork; you systematically approach failures using data and frameworks to build an ironclad case for root cause analysis

• You thrive in dynamic, cross-disciplinary environments. You enjoy working side-by-side with cross-functional teams, seamlessly closing gaps to solve multi-faceted system issues

• You are an impactful communicator. You can translate complex, highly technical electrical failure mechanisms into clear, concise, and actionable insights for both technical peers and executive stakeholders

• Bachelor's degree in Electrical Engineering, Physics, or a related technical discipline required

• Minimum 5-8+ years of direct, applicable experience in failure analysis, electrical troubleshooting, or reliability engineering

• Deep expertise in analyzing system-level electrical interactions, including hands-on experience identifying and mitigating EMC/EMI issues and environmental degradation

• Proficiency with common structured problem-solving methodologies (e.g., 8D, Ishikawa diagrams, 5-Why analysis)

• Strong verbal and written communication skills to construct clear FA reports and presenting technical data to cross-functional teams

• Experience with coaching or mentoring junior engineers or laboratory technicians

• Detail-oriented mindset with the ability to manage multiple priorities comfortably in a fast-paced, high-growth environment