Senior Process Engineer – Failure Analysis & Lab Lead

Plexus Corp.; Neenah, Northern (WI, KY); Hybrid; USD 77,000 - 116,000; Full time

Job summary

Plexus Corp. in Wisconsin is seeking a Senior Failure Analysis Engineer / Senior Process Engineer to provide technical guidance across the manufacturing process, driving quality improvements and supporting ongoing production activities.

The role involves leading root-cause analyses using a suite of lab techniques and mentoring engineers, with collaboration across R&D, design, quality, and manufacturing teams to turn FA insights into new product development.

Qualifications

• Bachelor's degree with 4+ years related experience preferred.
• Equivalent combination of education and experience considered.

Responsibilities

• Perform advanced destructive and non-destructive failure analysis to determine root causes.
• Operate lab equipment and techniques such as SEM, X-ray CT, EDS, XRF, Ion Chromatography, SIR, Dye & Pry, and decapsulation.
• Establish, update, and scale failure analysis workflows and SOPs.
• Deliver clear, detailed technical reports and failure analysis presentations to stakeholders.
• Provide mentorship and guidance to junior engineers and technicians.
• Partner with R&D, design, quality, and manufacturing to feed FA insights into NPI.
• Maintain a tour-ready lab and organized storage of supplies and samples.

Skills

Analytical skills

Statistical analysis

SPC software

Cross-functional collaboration

Written communication

Verbal communication

Lab techniques

Problem solving

Education

Bachelor's degree in related field

Tools

SEM

X-ray CT

EDS

XRF

Ion Chromatography

SIR

Dye & Pry

Decapsulation

Micro-section

Job description

Plexus Corp. in Wisconsin is seeking a Senior Failure Analysis Engineer / Senior Process Engineer to provide technical guidance across the manufacturing process, driving quality improvements and supporting ongoing production activities.

The role involves leading root-cause analyses using a suite of lab techniques and mentoring engineers, with collaboration across R&D, design, quality, and manufacturing teams to turn FA insights into new product development.