Failure Analysis Engineer

Failure Analysis Engineer

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:

We are looking for a motivated Failure Analysis Engineer ready to take us to the next level! If you have materials engineering expertise, hands-on failure analysis experience, and strong problem-solving skills, and are looking for your next career move, apply now.

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:

• 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

• 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.

Reasonable accommodation statement:
If you require a reasonable accommodation in completing this…