Manufacturing Failure Analysis Engineer Jobs (NOW HIRING)

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CAI is a global services firm with over 9,000 associates worldwide and a yearly revenue of $1.3 billion+. We have over 40 years of excellence in uniting talent and technology to power the possible for our clients, colleagues, and communities. As a privately held company, we have the freedom and focus to do what is right—whatever it takes. Our tailor-made solutions create lasting results across the public and commercial sectors, and we are trailblazers in bringing neurodiversity to the enterprise.

Job Summary

Job Description

We are looking for a Failure Analysis Engineer to be a crucial member of the Failure Analysis and Engineering team responsible for investigating product failures, manufacturing issues, customer complaints, and field returns. This position will be Full-Time and On-Site in Hampton, VA.

Export Control Requirement
This position involves access to information and hardware subject to the International Traffic in Arms Regulations (ITAR) and/or Export Administration Regulations (EAR). Candidates must be a U.S. Person as defined by ITAR (U.S. citizen, U.S. permanent resident, or protected individual).

What You’ll Do

• Perform failure analysis on customer returns, warranty claims, manufacturing defects, reliability failures, and field returns

• Conduct non-destructive and destructive analysis to determine failure modes and mechanisms

• Utilize analytical techniques, including microscopy, cross-section analysis, material characterization, X-ray inspection, and SEM/EDS

• Prepare samples and perform laboratory investigations according to established procedures and best practices

• Generate clear and concise technical reports documenting observations, findings, conclusions, and recommendations

• Support root cause investigations using structured methodologies such as 8D, 5 Why, Fishbone, Fault Tree Analysis (FTA), and/or Red X

• Collaborate with Product Engineering, Manufacturing Engineering, Quality Engineering, and Operations teams to resolve complex technical issues

• Participate in customer complaint investigations and provide technical evidence supporting corrective and preventive actions

• Support manufacturing sites in resolving scrap, yield, process, and field reliability issues

• Analyze trends in failure data and identify recurring failure mechanisms or systemic issues

• Contribute to product reliability improvements through understanding failure mechanisms and risk reduction recommendations

• Support DFMEA, PFMEA, and Lessons Learned activities through technical findings

• Maintain records, analysis reports, and documentation in compliance with applicable quality management system requirements

• Participate in continuous improvement initiatives focused on quality, reliability, cost reduction, and customer satisfaction

• Work effectively in a cross-functional and global environment supporting multiple manufacturing sites and business units

What You'll Need

Required:

• B.S. degree in Materials Engineering, Mechanical Engineering, Electrical Engineering, Physics, Chemistry, or related technical field

• Minimum 3-5 years of experience in Failure Analysis, Materials Engineering, Reliability Engineering, Product Engineering, Quality Engineering, or related technical discipline

• Hands-on experience performing root cause investigations and failure analysis activities

• Knowledge of analytical and laboratory techniques such as microscopy, metallography, cross-sectioning, SEM/EDS, X-ray, FTIR, DSC, or related methods

• Strong understanding of engineering problem-solving methodologies including 8D, 5 Why, Fishbone, and Fault Tree Analysis

• Experience supporting customer complaint investigations and corrective action activities

• Ability to interpret technical drawings, specifications, product requirements, and engineering documentation

Preferred:

• Knowledge of quality systems and standards such as ISO 9001, IATF 16949, ISO 13485, or AS9100

• Experience using statistical software and analysis tools such as Minitab

• Six Sigma Green Belt, Red X, or equivalent problem-solving certification

• Excellent technical report writing and communication skills

• Ability to independently manage multiple investigations and prioritize activities

Physical Demands

• Ability to safely and successfully perform the essential job functions consistent with the ADA and other federal, state, and local standards

• Ability to conduct repetitive tasks on a computer, utilizing a mouse, keyboard, and monitor

• Must be able to communicate with customers and team members over the phone and in person

• Sedentary work that involves sitting or remaining stationary most of the time, with occasional need to move around the office to attend meetings, etc.

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Reasonable accommodation statement

If you require a reasonable accommodation in completing this application, interviewing, completing any pre-employment testing, or otherwise participating in the employment selection process, please direct your inquiries to application.accommodations@cai.io or (888) 824 – 8111.

EEO Statement

It is the policy of Computer Aid, Inc.(CAI) not to discriminate against any employee or applicant for employment because of race, color, religion, sex, sexual orientation, gender identity, national origin, age, marital status, genetic information, disability or because he or she is a protected veteran. It is also the policy of CAI to take affirmative action to employ and to advance in employment, all persons regardless of race, color, religion, sex, sexual orientation, gender identity, national origin, age, marital status, genetic information, disability or protected veteran status, and to base all employment decisions only on valid job requirements. This policy shall apply to all employment actions, including but not limited to recruitment, hiring, upgrading, promotion, transfer, demotion, layoff, recall, termination, rates of pay or other forms of compensation and selection for training, including apprenticeship, at all levels of employment.

Employees and applicants of CAI will not be subject to harassment on the basis of race, color, religion, sex, sexual orientation, gender identity, national origin, age, marital status, genetic information, disability or because he or she is a protected veteran. Additionally, retaliation, including intimidation, threats, or coercion, because an employee or applicant has objected to discrimination, engaged or may engage in filing a complaint, assisted in a review, investigation, or hearing or have otherwise sought to obtain their legal rights under any Federal, State, or local EEO law is prohibited.

The pay range for this position is listed above. Exact compensation may vary based on several factors, including location, experience, and education. Benefit packages include medical, dental, and vision insurance, as well as 401k retirement account access. Employees in this role may also be entitled to paid sick leave and/or other paid time off as provided by applicable law.