FA Engineer

Job Title: Failure Analysis Engineer

Job Summary
Responsible for performing failure analysis and root cause investigation on product, process, and customer-related quality issues. The role works closely with Quality, Engineering, Production, NPI, and customers to identify failure mechanisms, implement corrective actions, and prevent recurrence.

Job Responsibilities

1. Perform failure analysis on defective, rejected, or returned products to identify the root cause and failure mechanism.
2. Conduct systematic root cause analysis using tools such as 5 Why, Fishbone Diagram, 8D, DMAIC, FMEA, and Fault Tree Analysis.
3. Coordinate and conduct investigations involving dimensional, mechanical, material, process, and functional-related failures.
4. Prepare detailed Failure Analysis Reports, 8D reports, corrective action reports, and technical investigation summaries.
5. Work closely with Quality, Process, Production, NPI, Supplier Quality, and other relevant teams to implement corrective and preventive actions.
6. Support customer complaint investigations and provide timely technical findings, containment actions, root cause analysis, and corrective action responses.
7. Analyze production and quality data to identify recurring defects, abnormal trends, and potential failure risks.
8. Conduct verification and validation of corrective actions to ensure effectiveness and prevent recurrence.
9. Support investigation of failures during NPI, qualification, pilot builds, mass production, and reliability testing.
10. Review manufacturing processes, drawings, specifications, control plans, PFMEA, and inspection criteria as part of failure investigations.
11. Recommend process, tooling, material, design, or inspection improvements based on failure analysis findings.
12. Maintain proper documentation and traceability of FA cases, investigation results, corrective actions, and lessons learned.
13. Support internal, customer, and supplier audits related to product quality and failure investigation when required.
14. Drive continuous improvement initiatives to reduce defect rates, customer complaints, scrap, rework, and repeat failures.

Requirements

• Bachelor’s Degree in Mechanical Engineering, Manufacturing Engineering, Materials Engineering, Mechatronics, Electrical/Electronic Engineering, or a related discipline.
• Minimum 2–5 years of relevant experience in Failure Analysis, Quality Engineering, Process Engineering, Product Engineering, or manufacturing.
• Experience in manufacturing environments such as precision machining, die casting, semiconductor, electronics, automotive, or metal-based manufacturing is preferred.
• Strong knowledge of root cause analysis, 8D, FMEA, SPC, CAPA, and problem-solving methodologies.
• Familiarity with measurement and analytical equipment such as CMM, microscope, profile projector, hardness tester, surface roughness tester, XRF/X-ray, SEM/EDS, or other FA equipment would be an advantage.
• Good understanding of engineering drawings, GD&T, manufacturing processes, and product specifications.
• Strong analytical, troubleshooting, communication, and report-writing skills.
• Familiarity with ISO 9001 / IATF 16949 requirements would be an added advantage.
• Able to work cross-functionally and manage multiple failure investigations within required timelines.