Senior Automotive Failure Analysis Engineer

Auburn Hills, MI 48309

Our client, Automotive Manufacturing and Quality Engineering is seeking a Senior Automotive Failure Analysis Engineer to join their team. As a Senior Automotive Failure Analysis Engineer, you will be part of the Warranty Analysis and Resolution Engineering group supporting cross-functional quality and product reliability efforts. The ideal candidate will have strong analytical problem-solving, a disciplined approach to root cause investigation, and the confidence to communicate technical findings clearly across engineering, manufacturing, service, and supplier partners.

• Perform detailed warranty part analysis and failure investigations for returned field components, ensuring thorough documentation and actionable outcomes.
• Conduct root cause analysis using engineering methodologies such as 8D, Fishbone, 5 Why, FMEA, and fault tree analysis to identify contributing factors.
• Support disposition activities including teardown analysis, repairability assessment, scrap/rework recommendations, and containment actions for failed components.
• Collaborate with quality, manufacturing, service, design engineering, and suppliers to drive corrective and preventive actions that improve product reliability and reduce warranty costs.
• Prepare technical reports, failure summaries, and engineering recommendations for leadership and cross-functional teams, while supporting supplier technical reviews and continuous improvement programs.

• Bachelors degree in Mechanical Engineering, Automotive Engineering, or a related engineering discipline.
• 10 years of experience in automotive warranty analysis, product engineering, quality engineering, or failure analysis.
• Strong understanding of automotive mechanical systems and fundamental engineering concepts, including experience with teardown analysis and component diagnostics.
• Ability to read and interpret CAD drawings, engineering specifications, GD&T, material specifications, tolerance stack-ups, and validation reports.
• Excellent communication and technical documentation skills, with proficiency in Microsoft Office and engineering data analysis platforms.

• Opportunity to make a direct impact on warranty reduction, reliability improvements, and customer satisfaction through disciplined failure analysis.
• Work closely with quality, manufacturing, service, suppliers, and product engineering teams to drive corrective and preventive actions.
• Use proven root cause and reliability methodologies (8D, Fishbone, 5 Why, FMEA, fault tree analysis) to turn field failures into engineering learning.
• Support compliance with automotive quality standards and processes including APQP, PPAP, DFMEA, and PFMEA.
• Contribute to continuous improvement programs focused on reducing recurring failures and improving component performance.

• Medical and Prescription Drug Plans
• Vision Plan
• Health Savings Account
• Health Flexible Spending Account
• Dependent Care Flexible Spending Account
• Supplemental Life Insurance
• Short Term and Long Term Disability Insurance
• Business Travel Insurance
• Weekly Pay