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Sr Failure Analysis Engineer Jobs (NOW HIRING)

Senior Failure Analysis Engineer

Santa Clara, CA ยท On-site

$122K - $168K/yr

We are seeking a highly skilled and motivated Failure Analysis Engineer to join our world-class Failure Analysis Lab. In this role, you won't just solve problems-you will work at the dynamic ...

Senior Failure Analysis Engineer

Santa Clara, CA ยท On-site

$122K - $168K/yr

We are seeking a highly skilled and motivated Failure Analysis Engineer to join our world-class Failure Analysis Lab. In this role, you won't just solve problems-you will work at the dynamic ...

Failure Analysis Engineer

Rancho Cordova, CA ยท On-site

$121K - $194K/yr

This Senior Failure Analysis Engineer will debug Solid State Drive (SSD) failures discovered during internal validation as well as field failures from our customers. They will need to work on variety ...

This Senior Failure Analysis Engineer will debug Solid State Drive (SSD) failures discovered during internal validation as well as field failures from our customers. They will need to work on variety ...

Failure Analysis Engineer Department: L10 /L11 Test Engineering Employment Type: Full Time Location: 868 Description FII USA, Inc ., a Foxconn Technology Group Company, is seeking a Failure Analysis ...

Failure Analysis Engineer Location: Nashua, NH Amphenol High Speed Products Group is the market leader for high speed, high bandwidth electrical connectors for the Telecom/Datacom market (Mobile ...

Showing results 21-40

Sr Failure Analysis Engineer information

See salary details

$59.5K

$126.6K

$183.5K

How much do sr failure analysis engineer jobs pay per year?

As of Sep 4, 2026, the average yearly pay for sr failure analysis engineer in the United States is $126,557.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,500.00 and $143,500.00 per year, depending on experience, location, and employer.

What does a Sr Failure Analysis Engineer do?

A Sr Failure Analysis Engineer investigates and determines the root causes of product or component failures in manufacturing or field environments. They use various analytical tools and techniques, such as microscopy, electrical testing, and material analysis, to examine failed products and recommend corrective actions. Their work helps improve product reliability, prevent recurring issues, and support quality assurance efforts. They also prepare detailed reports and collaborate with design, manufacturing, and quality teams to implement solutions.

What are some common challenges faced by a Sr Failure Analysis Engineer when working with cross-functional teams?

A Sr Failure Analysis Engineer often collaborates with design, manufacturing, and quality teams to identify the root causes of product failures. One common challenge is effectively communicating complex technical findings to non-engineering stakeholders and ensuring recommendations are clearly understood and actionable. Additionally, balancing multiple urgent failure investigations while maintaining detailed documentation and meeting tight deadlines can be demanding. Building strong cross-functional relationships and proactively sharing insights helps facilitate smoother collaboration and more successful problem resolution.

What are the key skills and qualifications needed to thrive as a Sr Failure Analysis Engineer, and why are they important?

To thrive as a Sr Failure Analysis Engineer, you need a strong background in materials science, electronics, and failure analysis methodologies, usually supported by a degree in engineering or a related field. Expertise with analytical tools such as SEM, TEM, FIB, and industry-standard failure analysis software is typically required, along with knowledge of quality standards like Six Sigma or IPC. Critical thinking, problem-solving, and clear communication are key soft skills for effectively diagnosing issues and presenting findings to cross-functional teams. These competencies are vital for accurately identifying root causes, preventing future failures, and driving continuous product improvement.

What is the difference between Sr Failure Analysis Engineer vs Failure Analysis Engineer?

AspectSr Failure Analysis EngineerFailure Analysis Engineer
Required CredentialsBachelor's or Master's in Engineering, certifications like ASQ FAI or relatedBachelor's or Master's in Engineering, similar certifications
Work EnvironmentManufacturing, electronics, aerospace, or automotive industriesSame industries, often in R&D or quality departments
Employer & Industry UsageUsed in large corporations, tech firms, manufacturing plantsCommon in similar settings, often as entry to mid-level roles

The main difference between a Sr Failure Analysis Engineer and a Failure Analysis Engineer lies in experience and responsibility. The senior role typically involves more complex analysis, mentorship, and project leadership, while the standard role focuses on executing failure investigations under supervision. Both roles require similar credentials and work in comparable environments, but the senior position indicates a higher level of expertise and accountability.

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Infographic showing various Sr Failure Analysis Engineer job openings in the United States as of August 2026, with employment types broken down into 86% Full Time, 12% Part Time, and 2% Contract. Highlights an 83% Physical, 4% Hybrid, and 13% Remote job distribution, with an average salary of $126,557 per year, or $60.8 per hour.

Senior Failure Analysis Engineer-ATS

PG&E Corporation

Danville, CA โ€ข On-site

$122K - $167K/yr

Full-time

Re-posted 18 days ago


Key responsibilities

  • Conduct failure analysis on a variety of components using principles of direct cause analysis.

  • Lead project teams in performing tests, defining problems, and preparing technical reports and recommendations.

  • Identify new solutions to complex problems and modify prototypes, parts, or systems to correct functional deviations.


Job description

Requisition ID # 173223 

Job Category: Engineering / Science 

Job Level: Individual Contributor

Business Unit: Energy Delivery

Work Type: Onsite

Job Location: San Ramon

Department Overview

Applied Technology Services (ATS) has been providing technology-based, innovative, high-value services to the company for over 40 years. ATS is a multidisciplinary team of over 120 engineers, scientists, and technicians. The ATS vision is to be a forward-thinking, technological leader providing high-value solutions and services needed across the Company. ATS high value services also help proactively avoid future problems by specifying equipment, materials and methods that are best practices in the industry.

 

Position Summary

The ATS Senior Failure Analysis Engineer is expected to execute failure analysis and materials testing projects. The engineer will support the planning, executing, and reporting as necessary. A candidate will have experience in testing/evaluating power system components along with providing consultation and advice to clients to proactively avoid future failures by specifying equipment, materials, and methods that are best practices in the industry.

A successful candidate will have demonstrated ability to independently lead failure analysis projects with previous experience in planning, executing, and reporting. A strong knowledge of metallurgy including understanding of variety material failure modes. Materials you will most likely encounter on the job are: Steels (pipes, valves, vessels), Aluminum (wire, fittings, connectors), Copper (wire, valves), and ceramics (insulators).  A suitable candidate will have experience using scientific methods and work experience analyzing test results including an in-depth knowledge of non-destructive (NDE), destructive examination techniques, and material/manufacturing processing techniques. The candidate will execute Risk Assessments like Failure Mode and Effects Analysis (FMEA) along with using advanced data analytics to integrate failure analysis and testing results into asset management strategies. Work duties may include: equipment failure analysis, engineering support for safety investigations, and general electrical engineering analysis.

PG&E is providing the salary range that the company in good faith believes it might pay for this position at the time of the job posting. This compensation range is specific to the locality of the job.  The actual salary paid to an individual will be based on multiple factors, including, but not limited to, specific skills, education, licenses or certifications, experience, market value, geographic location, and internal equity.  Although we estimate the successful candidate hired into this role will be placed towards the middle or entry point of the range, the decision will be made on a case-by-case basis related to these factors.

Bay Area Minimum: $122,000

Bay Area Mid:$158,000
Bay Area Maximum: $194,000

This job is also eligible to participate in PG&Eโ€™s discretionary incentive compensation programs. 

Responsibilities

  • Participate in multidisciplinary teams to conduct failure analysis on a variety of components using principles of direct cause analysis
  • Exercises independent judgment in leading and resolving problems of large impact, scope and complexity with few precedents or standards requiring integration of information from a variety of sources.
  • Leads project teams performing tests to identify, define, solve problems and prepare technical reports and specifications. Prepares and delivers presentations and recommendations to clients based on project results/findings.
  • May represent PG&E at industry association meetings or seminars.
  • Identifies new practical solutions to highly complex problems. Assesses business conditions, identifies opportunities and develops projects & solutions from a multifunctional or multidisciplinary perspective.
  • Modifies prototypes, parts, assemblies, and systems to correct functional deviations. Continually identifies testing or process improvements.

Qualifications

Minimum:

  • B.S. in Mechanical Engineering, Materials Engineering or similar
  • Job-related experience, 5 years

Desired:

  • M.S. in applicable fields
  • Minor or emphasis on mechanical/materials engineering
  • Licensed Professional Engineer (PE)
  • Consulting skills: communication, interpersonal and team collaboration skills.
  • Proficiency in engineering research and testing concepts, theories, practices, methods, techniques.
  • Thorough investigative skills
  • Understand quality assurance concepts and practices.
  • Analytical and organizational skills.
  • Basic team leadership and project management skills.