Senior Failure Analysis Engineer: Root Cause Expert

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

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