Senior Failure Analysis Engineer - Mechanical

Anker Innovations; Ontario (CA); On-site; CAD 118,000 - 167,000; Full time

Benefits offered by this job

10 Days Company Recognized Holidays

Paid time Off - up to 15 Days

401(k) and company match

Medical & Dental & Vision Insurance

Employee Assistance Program

Job summary

Anker Innovations is seeking an experienced Senior Failure Analysis Engineer to manage failure analysis of returned electronic products across our global portfolio. You will perform in-depth electrical and material analysis to identify root causes and translate findings into design and process improvements, working with R&D, Quality, Manufacturing and suppliers worldwide.

You will contribute to AI-enabled diagnostics, develop failure knowledge bases, and drive corrective actions using 8D

Qualifications

• Bachelor's degree in mechanical/related field; Master's preferred.
• 8+ years in mechanical/structural/material failure analysis or related field.
• Experience with SEM/EDS, metallography and NDT techniques.

Responsibilities

• Lead failure analyses from diagnosis to root-causes and CAPA closure.
• Perform product teardown and material characterization to identify failure modes.
• Apply 8D and other root-cause methodologies to guide corrective actions.
• Collaborate with R&D, Quality, Manufacturing and global teams to implement improvements.
• Develop standardized failure analysis reports and maintain knowledge bases.

Skills

Failure analysis

Root cause analysis

CAPA experience

8D reports

Education

Bachelor's in Mechanical Engineering

Master's degree preferred

Tools

SEM

EDS

Metallography

NDT

Job description

Anker Innovations is a global leader in smart charging technologies and a developer of consumer products for the home, car, and mobile life. Founded in 2011, we've brought our products to 100+ countries and regions with more than 140 million users and a revenue of 2000+ million USD in 2022.

Anker Innovations has successfully built Anker, a world-renowned high-end innovative charging brand, and launched intelligent hardware brands such as Eufy, Nebula, and Soundcore to further explore smart charging, smart voice, smart home and other fields.

Today, we have a total of 4000+ employees in 15 offices across North America, Europe, Australia, Asia, LATAM and the Middle East. We are always looking for top talents like you.

For more information, please visit: https://us.anker.com/

Location: Onsite at Ontario, California

About the Role：

We are seeking an experienced Senior Failure Analysis Engineer to manage failure analysis of returned electronic and electrical products (RMA) across our global product portfolio.

In this role, you will perform in-depth electrical and component-level analysis to identify root causes of complex hardware failures and translate findings into actionable improvements across product design, manufacturing processes, and component quality. You will work closely with R&D, Quality, Manufacturing, and other cross-functional teams globally to drive issues through resolution.

You will also contribute to the development of our failure analysis knowledge base and AI-enabled diagnostic capabilities, helping transform engineering expertise and historical failure data into scalable diagnostic methodologies and intelligent tools.

Key Responsibilities:

• Own technical failure analysis of RMA products involving mechanical, structural, and materials-related issues, driving investigations from initial diagnosis through root-cause identification and closure.
• Perform product teardown and component-level physical diagnostics to identify failure mechanisms and determine root causes.
• Conduct mechanical and structural investigations using techniques such as dimensional and tolerance analysis, stress/fatigue analysis, leak and sealing integrity testing, fracture analysis, metallography, and non-destructive testing (NDT).
• Perform or interpret advanced material characterization and fracture analysis, including Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray Spectroscopy (EDS), and metallographic analysis, as applicable.
• Investigate failures related to mechanical design, manufacturing processes, assembly, materials, interfaces, sealing systems, and environmental or usage conditions.
• Apply structured root cause analysis methodologies to distinguish among design-, manufacturing-, material/component-, and use-related failure mechanisms and recommend appropriate corrective and preventive actions.
• Execute failure investigations in accordance with established 8D methodologies, including D4 root-cause analysis and verification at the component level.
• Support established turnaround targets for initial assessment, in-depth analysis, root-cause identification, and issue closure.
• Partner closely with R&D, Quality, Manufacturing, Supplier Quality, and other engineering teams to translate failure analysis findings into improvements in product design, manufacturing processes, assembly methods, and material/component quality.
• Provide technical data, physical evidence, and engineering analysis to support corrective actions and long-term product quality improvements.
• Participate in recurring technical reviews with globally distributed engineering and quality teams, ensuring that failure symptoms, investigative findings, root causes, and recommended actions are communicated accurately and systematically.
• Drive complex technical issues across functional and geographic boundaries through investigation and resolution.
• Develop comprehensive and standardized failure analysis reports, including technical reports, documenting failure symptoms, investigative methods, physical evidence, root causes, and recommended corrective actions.
• Capture recurring mechanical and structural failure modes, root causes, and corrective actions to continuously improve internal failure analysis methodologies and knowledge repositories.
• Contribute to the development and maintenance of failure case libraries, root-cause databases, diagnostic standards, and engineering best practices.
• Help establish consistent criteria for classifying product failures, including distinctions among design, manufacturing, material/component, and use-related causes.
• Support the development of AI-enabled failure analysis tools and diagnostic agents by translating mechanical and materials failure expertise, failure patterns, and diagnostic logic into structured rules and knowledge that can be leveraged by AI systems.
• Identify opportunities to improve failure analysis efficiency, diagnostic accuracy, and overall issue-resolution processes.

Basic Qualifications:

• Bachelor's degree in Mechanical Engineering, Materials Science & Engineering, Materials Engineering, or a related technical discipline; Master's degree preferred.
• 8+ years of professional experience in mechanical, structural, materials, or product failure analysis, reliability engineering, product quality engineering, or a closely related field.
• Demonstrated ability to independently perform component-level failure analysis, identify complex root causes, and develop technically sound corrective action recommendations.
• Strong knowledge of mechanical and structural failure mechanisms, including fracture, fatigue, deformation, wear, material degradation, assembly/process-related defects, sealing failures, and tolerance-related issues.
• Hands‑on experience with failure analysis and material characterization techniques such as SEM/EDS, metallography, mechanical property testing, non‑destructive testing (NDT), dimensional inspection, and leak/sealing integrity testing.
• Strong understanding of manufacturing processes, mechanical interfaces, tolerance stack‑up, material behavior, and their relationship to product reliability and failure mechanisms.
• Strong knowledge of structured root cause analysis methodologies, including 5 Whys, Fault Tree Analysis (FTA), Fishbone/Ishikawa analysis, and Design of Experiments (DOE).
• Experience developing 8D reports and managing corrective and preventive actions (CAPA) through closure.
• Strong technical communication and documentation skills, including the ability to independently prepare detailed failure analysis reports.
• Ability to collaborate effectively with globally distributed engineering teams.

Preferred Qualifications:

• Experience performing mechanical or materials failure analysis for consumer electronics, IoT devices, smart hardware, robotics, automotive or other high-volume manufactured products.
• Experience developing or standardizing mechanical failure analysis methodologies, diagnostic standards, design guidelines, or failure‑classification criteria.
• Experience building or maintaining failure case databases, engineering knowledge bases, or structured root‑cause repositories.
• Experience applying AI, machine learning, knowledge systems, or AI‑assisted diagnostic tools to engineering or failure analysis workflows.
• Demonstrated experience independently leading complex cross‑functional failure investigations or engineering projects.
• Previous technical leadership, mentoring, or team leadership experience is a plus.

This role works closely with engineering and quality teams across multiple regions, including teams based in China. Some flexibility for cross‑time‑zone collaboration is required, including approximately two evening virtual meetings per week, depending on business and project needs. We strive to schedule cross‑regional collaboration thoughtfully and provide reasonable flexibility around working hours when evening meetings are required.

Perks of Benefits:

• 10 Days Company Recognized Holidays
• Paid time Off - up to 15 Days
• 401(k) and company match
• Medical & Dental & Vision Insurance Coverage
• Employee Assistant Program

The base salary range for this position in the selected city is $85,000 - $120,000 annually. Compensation may vary outside of this range depending on a number of factors, including a candidate’s qualifications, skills, competencies and experience, and location.

Base pay is one part of the Total Package that is provided to compensate and recognize employees for their work, and this role is eligible for additional discretionary bonuses/ incentives/ restricted stock units.

Anker Innovations is committed to a diverse and inclusive workplace. Anker Innovations is an equal opportunity employer and does not discriminate based on race, national origin, gender, gender identity, sexual orientation, protected veteran status, disability, age, or other legally protected status. Please contact [e-mail] if you have any questions.