Sr. Systems Reliability Engineer

Zone 5 Technologies; United States; On-site; USD 148,000 - 219,000; Full time

Benefits offered by this job

Medical, dental, vision benefits

401k with company-match

Paid time off (3 weeks)

12 annual holidays

Job summary

Zone 5 Technologies seeks a Senior Systems Reliability Engineer to lead R&M activities across the product lifecycle for unmanned aircraft systems. You will drive RAM-C documentation, lead FMEA/FMECA, FTA, and RBD analyses, and develop reliability predictions with traceability to requirements.

Engage customers during reviews and MIL-STD-driven assessments to ensure program success. The role focuses on R&M architecture, data-driven analysis, test planning, and documentation, with

Qualifications

• 7+ years in reliability engineering roles.
• Experience with MIL-STD-785, MIL-HDBK-217 and related R&M standards.
• Experience owning FRACAS, including failure tracking and corrective action closure.
• Proven experience developing and executing reliability test plans and growth tests.
• Experience engaging with customers on R&M reviews and milestone/design reviews.

Responsibilities

• Develop and maintain the RAM-C reliability architecture documentation.
• Lead FMEA/FMECA, FTA, and RBD across system architecture.
• Draft reliability predictions and maintainability analyses with traceability to requirements.
• Lead RCMS and LORA activities and support BIT analysis.
• Present R&M analyses and risk posture at Milestone Reviews and design reviews.
• Coordinate responses to customer R&M data deliverables.

Skills

Reliability engineering

RAM-C documentation

FMEA/FMECA

FTA analysis

RBD experience

Customer engagement

Technical writing

System architecture

Education

Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics

Master's degree in engineering

Tools

FRACAS tooling

FMEA software

RAM-C tooling

Job description

At Zone 5 Technologies, we're redefining what's possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting-edge autonomous solutions that push the boundaries of UAS technology - solving complex challenges that matter.

We're building the future of UAS capabilities, and we're looking for exceptional talent to join us. If you're driven by hard problems, energized by rapid innovation, and ready to make an impact on next-generation flight systems, you belong here.

We are seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle. This role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. You will engage directly with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews.

Key Responsibilities:

Reliability & Maintainability Architecture

• Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C (Reliability, Availability, Maintainability-Cost) Rationale Report
• Lead Failure Modes, Effects, and Criticality Analysis (FMEA/FMECA), Fault Tree Analysis (FTA), and Reliability Block Diagram (RBD) development across system architecture
• Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support R&M requirements analysis and trade studies
• Draft Reliability Predictions (per MIL-HDBK-217 and related methods) and Maintainability Analyses; maintain traceability between R&M requirements, predictions, and demonstrated performance
• Lead Reliability-Centered Maintenance (RCM) and Level of Repair Analysis (LORA); support Testability and Built-In Test (BIT) analysis

Data, Documentation & Test Planning

• Establish and own the Failure Reporting, Analysis, and Corrective Action System (FRACAS); maintain closed-loop failure data collection and trending from design through test, production, and sustainment
• Develop Failure Definitions and Scoring Criteria (FDSC) and reliability test plans tied to program milestones
• Lead reliability growth planning and execution of reliability growth and demonstration testing, including Environmental Stress Screening (ESS) and HALT/HASS where applicable
• Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments
• Develop technical documentation including R&M standards, specifications, procedures, and user guides
• Review ground test, flight test, and live-fire test data to confirm R&M requirements compliance
• Serve as primary point of contact with customers on R&M matters
• Present R&M analyses, RAM-C Rationale Report updates, and risk posture at Milestone Reviews (A/B/C) and design reviews (PDR, CDR, TRR, PRR)
• Lead Reliability Scoring Conferences and Corrective Action Boards (CAB) with customer participation
• Coordinate responses to customer R&M data item deliverables and support In-Service Reviews

Risk Management & Process Improvement

• Lead Root Cause and Corrective Action (RCCA) investigations for failures identified through FRACAS
• Host corrective action reviews and ensure lessons learned are implemented across the program
• Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence and shelf-life and aging surveillance considerations
• Apply digital engineering and AI-enabled tools (predictive maintenance, digital twins, automated FRACAS analytics) to R&M processes
• Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards

Basic Qualifications:

• 7+ years as a Reliability Engineer, R&M Engineer, or equivalent reliability-critical engineering role
• Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics
• Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards
• Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure
• Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening
• Experience engaging with customers on R&M reviews and milestone/design reviews (PDR, CDR, Milestone B/C)
• Strong system architecture knowledge and R&M requirements decomposition and allocation
• Extensive FMEA/FMECA, FTA, and RBD experience
• Failure investigation with proven corrective action implementation
• Technical writing for R&M program plans, rationale reports, procedures, and documentation
• Design review experience (PDR, CDR, MRR) with strong presentation skills
• Data collection, analysis, and trending for R&M metrics

Preferred Qualifications:

• Master's degree in engineering or related field
• 10+ years progressive R&M experience
• ASQ Certified Reliability Engineer (CRE) or equivalent certification
• DoD or Navy R&M programs experience, aligned with SECNAV Reliability and Maintainability Engineering guidance
• Quantitative reliability growth modeling (e.g., Crow-AMSAA) and Weibull analysis
• Maintainability, Testability/BIT, LORA, and RCM experience
• Missile, hypersonic, or munitions systems experience, including all-up-round reliability, environmental stress screening, and shelf-life/stockpile surveillance programs
• Digital engineering and AI-enabled R&M tools (predictive maintenance, digital twins, automated FRACAS analytics)
• Active U.S. Security Clearance or ability to obtain

Level IV - $148k - $180k Level V - $180k - $219k

Pay range for this role

$148,000 - $219,000 USD

What's in it for you:

• Comprehensive benefit package options include medical, dental, vision, life, and more.
• 401k with company-match
• 3 weeks of paid time off each year
• 40 hours of sick time
• 12 annual company holidays

Why Join Zone 5 Technologies?

• Innovative Environment: Work on cutting-edge technology that is shaping the future of defense and aerospace.
• Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what’s possible.
• Career Growth: Opportunities for professional development and career advancement.

If you are passionate about unmanned aircraft technology and want to be a part of a dynamic and growing company, we would love to hear from you.

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Zone 5 Technologies is a federal contractor and participates in E-Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E-Verify system. Learn more about your rights and responsibilities under E-Verify: https://www.e-verify.gov .

Our contracts with the United States Department of Defense require that all Zone 5 Technologies employees are US Citizens- are you currently a US Citizen?

Are you authorized to work in the United States?

Will you now or in the future require sponsorship from Zone 5 Technologies for employment (e.g, H-1B visa)?

Are you at least 18 years of age?

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For government reporting purposes, we ask candidates to respond to the below self-identification survey.Completion of the form is entirely voluntary. Whatever your decision, it will not be considered in the hiringprocess or thereafter. Any information that you do provide will be recorded and maintained in aconfidential file.

As set forth in Zone 5 Technologies’s Equal Employment Opportunity policy,we do not discriminate on the basis of any protected group status under any applicable law.

If you believe you belong to any of the categories of protected veterans listed below, please indicate by making the appropriate selection.As a government contractor subject to the Vietnam Era Veterans Readjustment Assistance Act (VEVRAA), we request this information in order to measurethe effectiveness of the outreach and positive recruitment efforts we undertake pursuant to VEVRAA. Classification of protected categoriesis as follows:

A "disabled veteran" is one of the following: a veteran of the U.S. military, ground, naval or air service who is entitled to compensation (or who but for the receipt of military retired pay would be entitled to compensation) under laws administered by the Secretary of Veterans Affairs; or a person who was discharged or released from active duty because of a service-connected disability.

A "recently separated veteran" means any veteran during the three-year period beginning on the date of such veteran's discharge or release from active duty in the U.S. military, ground, naval, or air service.

An "active duty wartime or campaign badge veteran" means a veteran who served on active duty in the U.S. military, ground, naval or air service during a war, or in a campaign or expedition for which a campaign badge has been authorized under the laws administered by the Department of Defense.

An "Armed forces service medal veteran" means a veteran who, while serving on active duty in the U.S. military, ground, naval or air service, participated in a United States military operation for which an Armed Forces service medal was awarded pursuant to Executive Order 12985.