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Failure Analysis Jobs in Wisconsin (NOW HIRING)

A.O. Smith

Materials Engineer - Polymers

Milwaukee, WI · On-site

  • Medical

  • Dental

  • Life

  • Retirement

Lead materials-related failure analysis and root cause investigations for plastics, rubbers, elastomers, seals, gaskets, molded components, and other polymeric materials, including development of ...

A. O. Smith

Materials Engineer - Polymers

Milwaukee, WI · On-site

  • Medical

  • Dental

  • Life

  • Retirement

Lead materials-related failure analysis and root cause investigations for plastics, rubbers, elastomers, seals, gaskets, molded components, and other polymeric materials, including development of ...

Milwaukee Tool

Senior Materials Engineer, Polymers

Brookfield, WI · On-site

$98K - $135K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

Perform root cause failure analysis of field & test failures * Self-motivation to lead material/process investigations to solve and/or prevent quality issues * Provideas-neededsupport tosuppliers ...

Lund Boats

Maintenance Engineer

Fond Du Lac, WI · On-site

$73K - $117K/yr

  • Medical

  • Dental

  • Vision

  • Retirement

  • PTO

By leveraging failure analysis, data collection, industry best practices, and technology, the engineer will recommend solutions that enhance equipment uptime and overall production availability. At ...

Harley-Davidson

Sr Engineer Materials - Steel Systems

Wauwatosa, WI · On-site

$101K - $139K/yr

  • Medical

  • Retirement

The engineer leads material-related problem solving, including failure analysis and root cause investigations, with an emphasis on durability, fatigue performance, and heat treatment control of steel ...

Milwaukee Tool

Senior Materials Engineer, Polymers

Brookfield, WI · On-site

$98K - $135K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

Perform root cause failure analysis of field & test failures * Self-motivation to lead material/process investigations to solve and/or prevent quality issues * Provide as-needed support to suppliers ...

Brunswick Corporation

Maintenance Engineer

Fond Du Lac, WI · On-site

$73K - $117K/yr

  • Medical

  • Dental

  • Vision

  • Retirement

  • PTO

By leveraging failure analysis, data collection, industry best practices, and technology, the engineer will recommend solutions that enhance equipment uptime and overall production availability. At ...

Brunswick

Maintenance Engineer

Fond Du Lac, WI

$73K - $117K/yr

  • Medical

  • Dental

  • Vision

  • Retirement

  • PTO

By leveraging failure analysis, data collection, industry best practices, and technology, the engineer will recommend solutions that enhance equipment uptime and overall production availability. At ...

Specialty Granules LLC (SGI)

Reliability Engineer

Pembine, WI · On-site

$94K - $118K/yr

  • PTO

Using root cause failure analysis techniques, plus through oversight of the FRACAS Team, implements corrective actions to reduce the impact or eliminate the losses. Core Competencies * Must be able ...

Specialty Granules

Reliability Engineer

Pembine, WI

$94K - $118K/yr

  • PTO

Using root cause failure analysis techniques, plus through oversight of the FRACAS Team, implements corrective actions to reduce the impact or eliminate the losses. Core Competencies * Must be able ...

Foxconn WI

RMA Manager

Mount Pleasant, WI · On-site

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Collaborate with Repair, Failure Analysis, Quality, and Customer Quality teams to determine root cause and disposition of returned units * Establish and maintain RMA procedures, work instructions ...

Sanmina

RMA Repair Technician

Pleasant Prairie, WI · On-site

Write detailed failure analysis reports and update repair logs Help in maintaining and establishing processes and procedures to ensure that RMA's are processed and closed in a timely manner ...

Foxconn WI

RMA Manager

Mount Pleasant, WI · On-site

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Collaborate with Repair, Failure Analysis, Quality, and Customer Quality teams to determine root cause and disposition of returned units * Establish and maintain RMA procedures, work instructions ...

Outlook group

Maintenance Technician

Neenah, WI · On-site

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Perform failure analysis and recommend changes * Read and interpret schematic diagrams, technical manuals, and blueprints. * Work with, and provide direction to outside contractors as needed

Capgemini

WI · On-site

$99K - $125K/yr

... Analysing test data to identify failure mechanisms, leading failure analysis activities, and driving corrective actions in collaboration with design, process, and test teams to ensure product ...

Capgemini

WI · On-site

$99K - $125K/yr

... Analysing test data to identify failure mechanisms, leading failure analysis activities, and driving corrective actions in collaboration with design, process, and test teams to ensure product ...

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Showing results 21-40

All JobsFailure Analysis JobsFailure Analysis Jobs in Wisconsin

Failure Analysis information

See Wisconsin salary details

$15

$28

$42

How much do failure analysis jobs pay per hour?

As of Aug 13, 2026, the average hourly pay for failure analysis in Wisconsin is $28.20, according to ZipRecruiter salary data. Most workers in this role earn between $24.28 and $30.10 per hour, depending on experience, location, and employer.

What are common challenges in a failure analysis role and how are they addressed?

Professionals in Failure Analysis often encounter challenges such as isolating the root cause of complex failures, working with incomplete data, and meeting tight deadlines for critical product investigations. These challenges are typically addressed through a systematic approach—using advanced analytical tools, collaborating closely with cross-functional teams like engineering and quality assurance, and maintaining clear documentation. Continuous learning and staying updated with the latest testing methodologies also help in effectively overcoming obstacles in this dynamic field.

How to become a failure analysis engineer?

To become a failure analysis engineer, typically a bachelor's degree in materials science, mechanical engineering, or a related field is required. Gaining experience with failure analysis techniques, such as microscopy and testing methods, and obtaining certifications like Certified Failure Analysis Professional can enhance job prospects. Strong problem-solving skills and familiarity with industry standards are also important.

What skills and qualifications are needed for a failure analysis engineer?

To thrive as a Failure Analysis Engineer, you need a solid background in materials science, engineering, or physics, with strong analytical and problem-solving abilities. Familiarity with laboratory tools such as scanning electron microscopes (SEM), energy-dispersive X-ray spectroscopy (EDX), and relevant software for data analysis is typically required. Attention to detail, effective communication, and teamwork are crucial soft skills for documenting findings and collaborating with cross-functional teams. These competencies ensure accurate root-cause identification and effective solutions, which are vital for improving product reliability and reducing costly defects.

What is failure analysis?

Failure analysis is the process of investigating why a component, system, or material has failed in service or during testing. The goal is to determine the root cause of the failure, which can involve examining physical evidence, collecting data, and performing laboratory tests such as microscopy or chemical analysis. This information helps organizations prevent future failures, improve product design, and ensure safety and reliability. Failure analysis is commonly used in industries such as aerospace, automotive, electronics, and manufacturing.

What is the difference between Failure Analysis vs Materials Engineer?

AspectFailure AnalysisMaterials Engineer
Primary FocusInvestigating and diagnosing product failures to determine root causesDesigning, developing, and testing materials for product performance
Work EnvironmentLaboratories, manufacturing plants, failure investigation sitesResearch labs, manufacturing facilities, R&D departments
CertificationsOften requires certifications like ASQ Certified Failure AnalystTypically requires materials science degrees, possibly professional engineering licenses

Failure Analysis specialists focus on diagnosing why products fail, often working in labs or manufacturing settings. Materials Engineers design and develop materials to improve product performance. While both roles require technical knowledge of materials, Failure Analysis emphasizes troubleshooting and root cause analysis, whereas Materials Engineering centers on material development and testing.

What are popular job titles related to Failure Analysis jobs in Wisconsin?

For Failure Analysis jobs in Wisconsin, the most frequently searched job titles are:

What job categories do people searching Failure Analysis jobs in Wisconsin look for?

The top searched job categories for Failure Analysis jobs in Wisconsin are:

Failure Analysis jobs near you
Infographic showing various Failure Analysis job openings in Wisconsin as of August 2026, with employment types broken down into 1% Internship, 83% Full Time, 13% Part Time, and 3% Contract. Highlights an 82% Physical, 4% Hybrid, and 14% Remote job distribution, with an average salary of $58,651 per year, or $28.2 per hour.

Materials Engineer - Polymers

A. O. Smith Corporation

Milwaukee, WI • On-site

Full-time

Medical, Dental, Life, Retirement

Re-posted 25 days ago

A. O. Smith rating

6.8

Company rating: 6.8 out of 10

Based on 30 frontline employees who took The Breakroom Quiz

366th of 488 rated machine equipment manufacturers

Job description

Company / Location Information
A.O. Smith is a global leader applying innovative technologies and energy-efficient solutions to products manufactured and marketed worldwide. The company is one of the world's leading manufacturers of residential and commercial water heating equipment and boilers, as well as a manufacturer of water treatment products for residential and light commercial applications. A. O. Smith is headquartered in Milwaukee, Wisconsin, with approximately 12,000 employees at operations in the United States, Canada, China, India, Mexico, the Netherlands, and the United Kingdom.
Primary Function
The Materials Engineer - Polymers will be a part of our Lloyd R. Smith Corporate Technology Center (CTC) Team in Milwaukee, WI. The CTC contains a multidisciplinary team of engineers and technicians with the purpose of researching, developing, and supporting technologies on a 3-5 year time horizon. This role will serve as the organization's Subject Matter Expert for plastics, rubbers, elastomers, and other polymeric materials used in water heating and water treatment equipment. The engineer will support global business units, manufacturing plants, quality teams, sourcing, suppliers, and product engineering by providing technical guidance on material selection, qualification, failure analysis, root cause investigation, product performance issues, and application suitability. The role will also develop analytical approaches and test methods to assess material performance and will conduct forward-looking research into new materials, additives, compounds, processing methods, and manufacturing technologies.
Responsibilities
  • Serve as the organization's Subject Matter Expert for polymeric materials, including plastics and rubbers, and educate the organization on material behavior, degradation mechanisms, chemical compatibility, processing effects, supplier variation, emerging material technologies, and best practices for material selection and use.
  • Lead materials-related failure analysis and root cause investigations for plastics, rubbers, elastomers, seals, gaskets, molded components, and other polymeric materials, including development of structured investigation plans, use of appropriate characterization methods, interpretation of evidence, documentation of findings, and recommendations for corrective actions.
  • Provide technical support to business units, manufacturing plants, quality teams, sourcing, suppliers, and product engineering teams on polymer-related product complaints, performance issues, material substitutions, and application suitability questions; develop analytical approaches and test methods needed to assess material performance and application suitability.
  • Support business unit needs by making recommendations for selecting, evaluating, and qualifying polymeric materials, including thermoplastics, thermosets, rubbers, elastomers, and composite materials, for water-contact, high-temperature, pressure-bearing, sealing, and chemically exposed applications.
  • Conduct forward-looking research into new polymeric materials, additives, compounds, processing methods, manufacturing technologies, and supplier capabilities that could improve product performance, reliability, cost, sustainability, manufacturability, or competitive differentiation.
  • Work with internal and external testing labs to verify material and product performance, develop new test methods as needed, and translate test data into well-communicated, practical recommendations for design, quality, manufacturing, and supplier decisions.

Qualifications
  • Master's or PhD in Polymer Engineering, Materials Science, Chemical Engineering, Mechanical Engineering, or related field.
  • 7 years of relevant experience. Candidates with less experience may be considered based on depth of expertise.
  • Demonstrated expertise in polymer engineering, materials failure analysis, root cause investigation, and technical problem solving; experience with adjacent materials such as metals, enamels, foams, adhesives, or coatings is beneficial.
  • Significant experience with plastics, rubbers, elastomers, and polymer characterization methods, including mechanical testing, thermal analysis such as DSC, TGA, and DMA, rheology and melt flow evaluation, spectroscopy such as FTIR, microscopy including SEM/EDS, hardness testing, compression set, chemical compatibility and swelling evaluation, aging studies, and other methods used to assess polymer composition, degradation, processing effects, and application performance.
  • Experience evaluating polymer degradation, environmental stress cracking, chemical attack, swelling, embrittlement, creep, fatigue, wear, aging, compression set, sealing performance, and other application-specific failure modes.
  • Ability to document and communicate technical findings clearly to engineering, quality, manufacturing, sourcing, supplier, and leadership audiences through concise reports, presentations, and recommendations.
  • Great communication and organizational skills, including the ability to facilitate and foster good cross-functional, multi-disciplinary teamwork.
  • Strong time management and prioritization skills to balance multiple projects within a defined schedule and budget.
  • Domestic and International travel required.

Education
Bachelor's Degree in Engineering
We Offer
Competitive compensation package and comprehensive benefits plans which include medical and dental insurance, company-sponsored life insurance, retirement security savings plan, short- and long-term disability programs and tuition assistance.
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ADA Statement & EEO Statement
In developing this job description care was taken to include all competencies needed to successfully perform in this position. However, for Americans with Disabilities Act (ADA) purposes, the essential functions of the job may or may not have been described for purposes of ADA reasonable accommodation. All reasonable accommodation requests will be reviewed and evaluated on a case-by-case basis.
We consider all applicants for employment without regard to race, color, religion, gender, sexual orientation, national origin, age, disability, gender identity and expression, marital or military status. We also provide reasonable accommodations to qualified individuals with disabilities in accordance with the Americans with Disabilities Act and applicable state and local law.

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