Staff Electrical Failure Analysis Engineer (NJ

About the Role The Electrical Failure Analysis Engineer supports manufacturing and quality operations by leading electrical root cause analysis (RCA), failure characterization, and corrective action activities across server, rack, cable, connector, and electromechanical hardware platforms. This role focuses on identifying failure mechanisms, developing fault isolation methodologies, and driving systemic corrective actions to improve product quality, reliability, and manufacturing yield. The Electrical Failure Analysis Engineer works closely with Metrology Engineers, Supplier Quality Engineers, Manufacturing Engineering, Design Engineering, and Reliability teams to investigate electrical failures occurring during incoming inspection, manufacturing, system integration, qualification testing, and field operation.

This position applies electrical troubleshooting, statistical analysis, and structured problem‑solving methodologies to identify root causes and prevent recurrence in high-volume manufacturing environments.

• Lead electrical failure investigations involving connectors, cable assemblies, wire harnesses, power distribution systems, CB assemblies, and electromechanical components.
• Perform root cause analysis of electrical defects including opens, shorts, intermittent connections, excessive resistance, insulation breakdown, and ESD‑related failures.
• Develop and execute fault isolation plans using electrical test equipment and laboratory analysis techniques.
• Correlate electrical failure signatures with dimensional, mechanical, and metrology data to identify failure mechanisms and process drivers.
• Drive containment, corrective actions, and preventive actions through structured methodologies including &D, DMAIC, and CAPA processes.
• Partner with Manufacturing, Supplier Quality, and Engineering teams to resolve electrical nonconformances and improve product reliability.
• Develop electrical test methods, inspection procedures, and validation protocols to support manufacturing and quality operations.
• Support qualification, reliability, and environmental testing activities including thermal cycling. vibration, HALT, and HASS investigations.
• Analyze failure trends, field return data, and manufacturing defects to identify recurring issues and improvement opportunities.
• Review engineering drawings, schematics, wiring diagrams, and specifications to support failure analysis activities.
• Generate detailed technical reports documenting failure mechanisms, root causes, test results, and corrective actions.
• Support supplier audits, supplier corrective actions, and component qualification activities related to electrical and cable assembly suppliers.

• Bachelor's degree in Electrical Engineering, Electronics Engineering. Physics, or related technical field.
• 6+ years of experience in Electrical Failure Analysis, Hardware Quality Engineering, Reliability Engineering, Manufacturing Quality, or related disciplines.
• Strong troubleshooting experience with electrical and electronic systems.
• Hands‑on experience performing root cause investigations in manufacturing, quality, or reliability environments.
• Experience using structured problem‑solving methodologies including 8D, DMAIC, Fishbone Analysis, 5-Why, and FMEA.
• Experience with electrical test equipment including:
  • Digital Multimeters (DMM)
  • Oscilloscopes
  • LCR Meters
  • Power Supplies
  • Continuity Testers a Insulation Resistance Test Equipment
• Ability to read and interpret electrical schematics, wiring diagrams, assembly drawings, and specifications.
• Experience supporting supplier quality investigations and corrective action processes.
• Strong analytical skills with the ability to interpret data and identify failure trends.
• Excellent technical communication and report‑writing skills.

• Experience with Al servers, data center hardware, networking equipment, storage systems, or rack‑level integration.
• Experience with cable assemblies, wire harnesses, high‑current power systems, and connector reliability.
• Working knowledge of TDR (Time Domain Reflectometry) for cable and fault localization analysis.
• Experience using Vector Network Analyzers (VNA) and performing basic…