Sr. Systems Reliability Engineer
We are seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle. This role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. You will engage directly with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews.
Key Responsibilities:
Reliability & Maintainability Architecture
Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C (Reliability, Availability, Maintainability-Cost) Rationale Report
Lead Failure Modes, Effects, and Criticality Analysis (FMEA/FMECA), Fault Tree Analysis (FTA), and Reliability Block Diagram (RBD) development across system architecture
Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support R&M requirements analysis and trade studies
Draft Reliability Predictions (per MIL-HDBK-217 and related methods) and Maintainability Analyses; maintain traceability between R&M requirements, predictions, and demonstrated performance
Lead Reliability-Centered Maintenance (RCM) and Level of Repair Analysis (LORA); support Testability and Built-In Test (BIT) analysis
Data, Documentation & Test Planning
Establish and own the Failure Reporting, Analysis, and Corrective Action System (FRACAS); maintain closed-loop failure data collection and trending from design through test, production, and sustainment
Develop Failure Definitions and Scoring Criteria (FDSC) and reliability test plans tied to program milestones
Lead reliability growth planning and execution of reliability growth and demonstration testing, including Environmental Stress Screening (ESS) and HALT/HASS where applicable
Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments
Develop technical documentation including R&M standards, specifications, procedures, and user guides
Review ground test, flight test, and live-fire test data to confirm R&M requirements compliance
Customer Engagement & Reviews
Serve as primary point of contact with customers on R&M matters
Present R&M analyses, RAM-C Rationale Report updates, and risk posture at Milestone Reviews (A/B/C) and design reviews (PDR, CDR, TRR, PRR)
Lead Reliability Scoring Conferences and Corrective Action Boards (CAB) with customer participation
Coordinate responses to customer R&M data item deliverables and support In-Service Reviews
Risk Management & Process Improvement
Lead Root Cause and Corrective Action (RCCA) investigations for failures identified through FRACAS
Host corrective action reviews and ensure lessons learned are implemented across the program
Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence and shelf-life and aging surveillance considerations
Apply digital engineering and AI-enabled tools (predictive maintenance, digital twins, automated FRACAS analytics) to R&M processes
Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards
Basic Qualifications:
7+ years as a Reliability Engineer, R&M Engineer, or equivalent reliability-critical engineering role
Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics
Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards
Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure
Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening
Experience engaging with customers on R&M reviews and milestone/design reviews (PDR, CDR, Milestone B/C)
Strong system architecture knowledge and R&M requirements decomposition and allocation
Extensive FMEA/FMECA, FTA, and RBD experience
Failure investigation with proven corrective action implementation
Technical writing for R&M program plans, rationale reports, procedures, and documentation
Design review experience (PDR, CDR, MRR) with strong presentation skills
Data collection, analysis, and trending for R&M metrics
U.S. Citizenship
Preferred Qualifications:
Master's degree in engineering or related field
10+ years progressive R&M experience
ASQ Certified Reliability Engineer (CRE) or equivalent certification
DoD or Navy R&M programs experience, aligned with SECNAV Reliability and Maintainability Engineering guidance
Quantitative reliability growth modeling (e.g., Crow-AMSAA) and Weibull analysis
Maintainability, Testability/BIT, LORA, and RCM experience
Missile, hypersonic, or munitions systems experience, including all-up-round reliability, environmental stress screening, and shelf-life/stockpile surveillance programs
Digital engineering and AI-enabled R&M tools (predictive maintenance, digital twins, automated FRACAS analytics)
Active U.S. Security Clearance or ability to obtain
Level IV - $148k - $180k Level V - $180k - $219k
Pay range for this role
$148,000—$219,000 USD