Senior Reliability Engineer - Hybrid

Reliability Engineer

Wayne, NJ Secret Polygraph Unspecified Career Level not specified $105,827 - $179,906

Thank you for your interest in BAE Systems! This opening is included as part of our September 2026 Defense Electronics Engineering Hiring Event. While we encourage all interested professionals to apply, please note that this is a selection-based interview event for candidates whose skills and experience match our hiring needs. If your background and skill set match these needs, we will reach out with next steps.

If selected for an interview, specific opportunities based on your interests, experience, and skill set will be discussed with the hiring team. For candidates not local to the northern New Jersey area, virtual interviews will be accommodated. BAE Systems is a leading global defense, security, and aerospace company. We deliver a full range of products and services for air, land and naval forces, as well as advanced electronics, security, information technology solutions and customer support services.

We are experiencing significant growth, driven by innovation and a commitment to supporting our customers. Join us and be a part of something bigger! We are seeking a motivated and detail-oriented Reliability Engineer to join our dynamic team. You will play a vital role in ensuring the reliability and performance of our systems, working alongside experienced engineers and contributing to continuous improvement.

This role is designed for growth, with opportunities to expand your skill set and take on increasing responsibilities as you progress within the company.

Responsibilities include:

• Analyze failed hardware and software components from production and field returns to determine root cause of failures and assist in developing corrective actions. This includes understanding failure mechanisms and applying engineering principles to diagnose issues.
• Collaborate with internal teams (Quality, Hardware Design, Manufacturing, Software Engineering) to gather information, facilitate investigations, and implement solutions.
• Interface with Suppliers/Vendors to review their failure analysis findings, ensure alignment, and drive resolution of supplier-related issues.
• Perform detailed failure analysis using a variety of techniques (visual inspection, microscopy, component-level testing, data analysis, and potentially more advanced techniques like X-ray or SEM depending on your product).
• Author clear, concise, and technically accurate customer-facing failure reports and narratives, including recommended corrective actions and clear communication of technical issues.
• Maintain and update the FRACAS database with accurate failure data, analysis results, and corrective action tracking.
• Review and interpret data from manufacturing process monitoring, environmental stress screening (ESS), and system testing to identify potential reliability concerns.
• Collaborate with test teams to investigate failure modes, refine test procedures, and improve test coverage.

Reliability Data Analysis & Prediction

• Collect, analyze, and interpret reliability data from various sources (field failures, testing, simulations) to identify trends, potential areas for improvement, and quantify product reliability.
• Utilize statistical tools and techniques (Weibull analysis, MTBF/MTTR calculations, FMECA, Root Cause Analysis, hypothesis testing) to assess system reliability and predict future performance.
• Develop and maintain reliability prediction models to assess design margins and optimize product life.
• Perform Reliability Growth Analysis to track improvement over time.
• Contribute to the development of reliability test plans and strategies.

Maintainability & Testability Analysis

• Perform Maintainability analysis, estimate Mean Time To Repair (MTTR), and identify opportunities to improve product serviceability.
• Perform system-level testability analysis and demonstrate the effectiveness of diagnostic features.
• Support the development and implementation of diagnostic procedures to facilitate efficient troubleshooting.

Process Improvement & Quality Assurance

• Identify opportunities to improve manufacturing processes, design practices, and quality control procedures to reduce failure rates and enhance product reliability.
• Contribute to the development and implementation of corrective and preventative actions (CAPA).
• Participate in Design for Reliability (DFR) and Design for Manufacturability (DFM) reviews.
• Lead small-scale reliability improvement projects.

Documentation & Reporting

• Create and maintain detailed documentation of failure analysis results, test procedures, reliability data, and analysis reports.
• Prepare and deliver presentations summarizing reliability findings for internal stakeholders (engineering teams, management) and potentially external stakeholders (customers, vendors).

Required Education, Experience, & Skills

• Bachelor's degree in engineering (Electrical, Mechanical, Aerospace, Systems, or related field) with at least 4 years of experience (2…