Hardware Reliability Test Engineer- Onsite
Confirmed on the employer's own hiring board on Oct 27, 2026. First seen by Alion on Oct 26, 2026. Cognizant scores A on the Alion truth index.
"Applicants must be currently authorized to work for any employer in the United States. The company is unable to provide employment-based immigration sponsorship for this position."
Title: Hardware Reliability Test Engineer
Our Client Sunrise product development team requires specialized hardware reliability and environmental test engineering support to validate complex, in-house electronic modules for next-generation vehicles. Validate in-house electronic modules for next-generation vehicles. The work covers DFMEA, PFMEA and RCCA (5D/8D, 5-Why), environmental and reliability validation plans and test execution (thermal cycling, humidity, vibration, thermal shock, accelerated life), PCB inspection and destructive/chemical failure analysis per IPC, Weibull and CPK analysis, design reviews, and LabVIEW/TestStand test automation, all to Ford, AEC-Q, USCAR and ISO/IEC standards.
Requirements:
DFMEA/PFMEA/RCCA Documentation: Lead and document Design Failure Mode and Effects Analysis (DFMEA), Process Failure Mode and Effects Analysis (PFMEA), and Root Cause Corrective Action (RCCA) reports for electronic module hardware and manufacturing processes.
Validation Plans & Test Execution: Develop, maintain, and execute environmental and reliability validation plans, procedures, and test protocols, including temperature chamber cycling, humidity, vibration, thermal shock, and accelerated life-cycle testing.
Environmental Test Setup & Operation: Configure and operate environmental chambers, liquid chiller systems, and associated laboratory equipment; ensure test setups meet Ford and industry (AEC-Q, USCAR, ISO/IEC) requirements.
Failure & Chemical Analysis: Perform electronic PCB assembly inspection and destructive/chemical analysis processes (per IPC standards) to support root-cause failure analysis and design robustness assessments.
Reliability Modeling: Apply probabilistic reliability methods, Weibull failure-probability analysis, bogey testing, and accelerated life testing to characterize component and module reliability.
Statistical Data Analysis: Perform statistical analysis (histograms, CPK, trend analysis) of reliability and test data, using automation tools where applicable, to identify trends and recommend corrective actions.
Design Reviews: Participate in and provide expert guidance during design reviews, identifying potential failure modes and recommending reliability best practices for electronic module architecture.
Test System Software Automation: Support development and maintenance of automated test systems using NI LabVIEW and TestStand software to improve reliability test efficiency and repeatability.
Documentation & Reporting: Document and track reliability findings, corrective actions, and test results using Jira and Confluence, ensuring clear technical communication to technical and non-technical stakeholders.
Laboratory Management Support: When applicable, support laboratory management activities and maintenance of ISO/IEC-17025 (A2LA) accreditation compliance for the reliability test laboratory.
The engineer needs a BS in Electrical or Mechanical Engineering (MS preferred) and at least 3 years in electronic hardware reliability (5+ preferred), with automotive environmental test experience.
Work is onsite at Ford's Sunrise, Florida facility.