Senior Hardware Test Engineer - Reliability & Automation

BD; Durham (NC); On-site; USD 120,000 - 150,000; Full time

Job summary

BD is a global medical technology leader seeking an R&D Senior Hardware Test Engineer to develop automated electro‑mechanical test systems, drive reliability and life testing, and mentor junior staff. You will work with mechanical, electrical, and controls engineers to define test strategies, execute PQPs, and ensure robust verification of complex pharmacy automation devices.

Responsibilities include designing life-cycle test stands, performing FMEA analyses, and applying Weibull and other

Qualifications

• Proficient in LabVIEW programming and automated data acquisition.

Responsibilities

• Design and execute reliability, durability, and accelerated life test programs for electro-mechanical subsystems and full systems.
• Define reliability targets and test-to-failure strategies; determine sample sizes, run times, cycle counts, and confidence/reliability levels.
• Build and maintain long-duration life-cycle test stands with automated cycle counting, fault detection, and unattended run capability.
• Perform failure analysis and root cause investigation (FMEA, fault tree, 5-Why, 8D) and translate findings into design and test improvements.
• Apply life data analysis techniques (Weibull, MTBF/MCBF, hazard and survival plots, censored data) to quantify reliability growth and report trends and risks to program teams.
• Plan and execute designed experiments (full/fractional factorial, screening, response surface) to characterize system performance and identify critical factors.
• Define factors, levels, responses, blocking, and randomization; plan and execute Measurement System Analysis (MSA), including Gage R&R, to confirm test methods are repeatable and reproducible before running studies.
• Analyze results using ANOVA, regression, capability analysis (Cp/Cpk), and hypothesis testing in Minitab, Python, or JMP.
• Use DOE outputs to set design margins, tolerance windows, and robust operating parameters.
• Automate data aggregation, trending, and reporting so results are reproducible and audit-ready.
• Design electro-mechanical test systems and fixtures to support verification, validation, and reliability testing.
• Develop automated test workflows in LabVIEW including DAQ configuration, control logic, and data handling.
• Build integrated DAQ systems for sensors, motion control, communication technologies, and electro-mechanical devices.
• Improve or develop PLC- and microcontroller-based systems (e.g., DAQ, Arduino, Raspberry Pi platforms).
• Create benchmark programs and automated sequences to reduce machine downtime and accelerate troubleshooting.
• Review Product Qualification Plans (PQPs) and recommend additional test coverage, automation opportunities, and reliability improvements.
• Partner with mechanical, electrical, and controls engineers to create robust test plans for subsystems and prototypes.
• Perform hands‑on test execution when needed, ensuring accurate data capture and traceability.
• Champion statistically sound sampling and acceptance criteria within PQPs and verification protocols.
• Mentor junior engineers and test technicians in test setup, instrumentation, data integrity, and troubleshooting methodology.
• Coach the team on reliability and statistical concepts - sample size, variation, measurement error, and how to interpret results.
• Develop and deliver cross-training on LabVIEW, DAQ hardware, fixture use, and automated test sequences to broaden lab capability.
• Create clear work instructions, test protocols, and templates that enable technicians to run tests independently and consistently.
• Review test plans, data packages, and reports from others and provide constructive, specific technical feedback.
• Serve as a go‑to technical resource during test escalations and support onboarding of new engineers and technicians.
• Increase testing throughput and reduce downtime through parallel test setups, preventative maintenance, and system health monitoring.
• Design and assemble rapid prototypes and test fixtures to evaluate the feasibility of new concepts, including wiring, assembly, and instrumentation setup.
• Commission new test hardware and validate performance before release to the team.
• Troubleshoot complex electro-mechanical and automation issues and contribute to continuous improvement.

Skills

LabVIEW

DOE

Statistical analysis

Automation

Tools

DAQ hardware

LabVIEW

Arduino

Raspberry Pi

Job description

BD is a global medical technology leader seeking an R&D Senior Hardware Test Engineer to develop automated electro‑mechanical test systems, drive reliability and life testing, and mentor junior staff. You will work with mechanical, electrical, and controls engineers to define test strategies, execute PQPs, and ensure robust verification of complex pharmacy automation devices.

Responsibilities include designing life-cycle test stands, performing FMEA analyses, and applying Weibull and other