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Senior Root Cause Analysis Jobs (NOW HIRING)

Farmer Veteran Coalition

$16.50 - $21/hr

Your Role: Root Cause Investigator, Manufacturing OperationsAs the Root Cause Investigator ... Lead process improvement kaizens and drive process analytics discussions related to manufacturing ...

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How much do senior root cause analysis jobs pay per hour?

As of Sep 12, 2026, the average hourly pay for senior root cause analysis in the United States is $56.60, according to ZipRecruiter salary data. Most workers in this role earn between $48.08 and $64.42 per hour, depending on experience, location, and employer.

What is a senior root cause analysis specialist?

A Senior Root Cause Analysis (RCA) specialist is an experienced professional who investigates and identifies the underlying causes of problems or incidents within an organization. Their primary goal is to analyze complex issues, utilize various RCA methodologies (such as the 5 Whys, Fishbone Diagram, or Fault Tree Analysis), and recommend effective solutions to prevent recurrence. They often work across different departments, lead RCA investigations, and provide guidance and training to other team members. Senior RCA specialists play a critical role in improving processes, enhancing safety, and minimizing risks.

What are the key skills and qualifications needed to thrive as a senior root cause analysis specialist?

To thrive as a Senior Root Cause Analysis Specialist, you need expertise in problem-solving methodologies, data analysis, and process improvement, often backed by a degree in engineering, quality management, or a related field. Familiarity with tools like Six Sigma, Fishbone diagrams, 5 Whys, and data visualization software is typically required, along with relevant certifications such as Six Sigma Black Belt or Lean. Strong analytical thinking, communication, and cross-functional collaboration skills help professionals effectively identify issues and drive corrective actions. These skills are crucial for uncovering underlying problems, preventing recurrence, and supporting continuous improvement within organizations.

How does a senior root cause analysis specialist typically collaborate with cross-functional teams to resolve complex issues?

A Senior Root Cause Analysis specialist often works closely with engineers, quality assurance, operations, and management teams to thoroughly investigate incidents or recurring problems. They lead structured problem-solving sessions, facilitate data collection, and coordinate follow-up actions to ensure that solutions address the underlying causes. Effective collaboration is key, as these specialists must communicate findings clearly and drive consensus on corrective actions across different departments. This role frequently involves presenting detailed analysis to leadership and mentoring less experienced team members in best practices.

What is the difference between Senior Root Cause Analysis vs Root Cause Analysis?

AspectSenior Root Cause AnalysisRoot Cause Analysis
CredentialsTypically requires experience and certifications in quality management or process improvementUsually entry to mid-level, may require basic certifications or training
Work EnvironmentOften in manufacturing, engineering, or IT sectors, leading complex investigationsInvolves identifying causes in various industries, often as part of a team
Employer & Industry UsageUsed by organizations seeking advanced problem-solving expertiseCommon across industries for basic to moderate root cause investigations

Senior Root Cause Analysis professionals typically have more experience, advanced certifications, and handle complex investigations, whereas Root Cause Analysis roles are often entry to mid-level positions focused on identifying causes of issues. The senior role involves leadership and strategic problem-solving, while the basic role supports operational improvements.

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Senior Root Cause Analysis jobs near you
Infographic showing various Senior Root Cause Analysis job openings in the United States as of September 2026, with employment types broken down into 77% Full Time, 4% Part Time, and 19% Contract. Highlights an 92% In-person, 4% Hybrid, and 4% Remote job distribution, with an average salary of $117,737 per year, or $56.6 per hour.

Senior Analytical Engineer - Defect Analysis & Root Cause Investigation

San Antonio, TX • On-site

XPEL, Inc.
Motor Vehicle Parts Manufacturing • 201 - 500 employees
Learn more about XPEL, Inc.external

$94K - $129K/yr

Full-time

Re-posted 7 days ago

Key responsibilities

  • Lead and oversee the development of XPEL's core technologies.

  • Serve as the primary investigator for defect analysis across all process stages and apply structured root cause analysis workflow.

  • Lead surface analysis and imaging work, selecting and signing off on methods such as microscopy, SEM/EDS, AFM, XPS, and ToF-SIMS.

Job description

Job Summary:
This individual will be supporting XPEL's R&D activities while also lending support to analytical laboratory quality/Manufacturing teams as required across all of XPEL's product portfolio and help drive efficiency and expand on current capability as appropriate to XPEL's business needs. You must be able to thrive and succeed in an entrepreneurial environment, and not be hindered by ambiguity or competing priorities. The ideal candidate for this position is a detail-oriented individual with strong analytical and problem-solving skills, capable of understanding our products and acknowledging with ease its strengths and limitations with the intent to steer the development and evolution of our solutions. The candidate also has very strong communication skills and manages to communicate with a variety of stakeholders within XPEL.
The preferred location for this role will be at out of our office in San Antonio, TX. The Sr. R&D Engineer will report to the Director of Technology.
Core Duties:
  • Lead and oversee the development of XPEL's core technologies.
  • Serve as the lab's primary investigator for PPF/WPF manufacturing and field-return defects across all process stages, from raw material/melt prep through TPU extrusion, surface treatment, PSA lamination, topcoat cure, embossment, and slitting/storage.
  • Apply a structured RCA workflow: define the defect signature, preserve paired defect/control samples, separate optical/chemical/mechanical origin, localize to a layer or interface, confirm chemistry and process physics, validate cure/molecular state, reproduce on a controlled trial, and lock the fix into SPC.
  • Distinguish defect families (contamination, adhesion/interface, cure/crosslink, optical haze, thickness, migration/bloom, surface texture, thermal degradation, weathering, volatiles/moisture, mechanical, web handling) and select the right analytical pathway for each.
  • Lead all surface analysis and imaging work for the team, owning method selection and technical sign-off across stereo, optical cross-section, and polarized light microscopy, SEM/SEM-EDS, AFM, 3D optical profilometry/confocal microscopy, white-light interferometry, XPS, and ToF-SIMS.
  • Run thermal/molecular characterization (DSC, DMA, TGA, GPC/SEC, Karl Fischer), chromatography/mass spec (GC-MS, Py-GC/MS, LC-MS, ICP-OES/MS), mechanical/interfacial testing, and accelerated weathering to confirm chemistry and aging mechanisms.
  • Work with Quality/manufacturing, and supply chain to identify and secure key strategic materials for existing and new PPF, coatings, and related technologies
  • Provide robust technical solutions to new product development initiatives and lend support to sales and product management teams
  • Bridge the gap from bench scale testing to industrial manufacturing processes
  • Knowledge build and assess risk & factor all relevant industrial process & material validation on product performance through its life cycle
  • Develop plans and procedures for specifications & fabrication of components, integration of technologies, balancing cost & manufacturability
  • Serve as technical interface to vendors and manufacturers
  • Maintain meticulous documentation of work performed
  • Provide leadership to the junior technical team
  • Other duties as required.

Job Requirements:
  • Strong technical background in polymer/material science, coatings, and associated technologies
  • In-depth knowledge of coatings and/or adhesive chemistry, UV curing, photopolymerization applicable to industrial scale operations
  • Demonstrated experience leading root cause investigations in a polymer film, coatings, or adhesives manufacturing environment, ideally roll-to-roll/continuous web processing, with proven depth leading surface analysis and imaging work for a team.
  • Expert, hands-on command of surface analysis and imaging - SEM/SEM-EDS, AFM, 3D optical profilometry/confocal microscopy, white-light interferometry, XPS, and/or ToF-SIMS - sufficient to direct method selection and review others' work.
  • A background in thermal, mechanical, and optical properties for polymer multilayer films using advanced analytical tools like DMA/DHR, DSC, FTIR, TGA, profilometer, optical microscopy, etc.
  • Knowledge in polymer film processing, roll to roll, sheet extrusion and related technologies
  • Strong understanding of design of experiments and corresponding data analysis
  • Experience working with domestic and international vendors
  • Minimum of Bachelor's degree in Chemistry, Materials Science, Polymer Science, Chemical Engineering, or related STEM field, with 5-10 years of relevant analytical/materials lab experience. Advanced degree (MS/PhD) preferred.
  • Experience working with interdisciplinary teams to drive programs from concept to production/commercialization

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.
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About XPEL

Sourced by ZipRecruiter

Industry

Motor vehicle parts manufacturing

Company size

201 - 500 Employees

Headquarters location

San Antonio, TX, US

Social media

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