Staff Failure Analysis Engineer
About the Role
We are seeking an experienced Field Failure Analysis Engineer to lead deep-dive technical investigations into electromechanical, hardware, and system-level field failures across deployed Digit fleets. In this role, you bridge field operations, customer deployments, and engineering design teams to rapidly contain field escapes, definitively identify physics-of-failure mechanisms, and drive closed-loop corrective actions (CAPA) back into manufacturing and next-generation architecture.
About the Work
Drive Deep-Dive Physical & System FA: Lead end-to-end failure investigations on field-returned modules—including high-torque actuators, cycloidal/planetary gearboxes, high-strain cable harnesses, PCBAs, motor controllers, safety sensors (LiDAR/depth cameras), and battery management systems (BMS).
Telemetry & Log-Driven Triage: Correlate physical failure modes with fleet telemetry data, onboard CAN/EtherCAT bus logs, system crash dumps, and time-series sensor data to reproduce field anomalies in lab environments.
Own 8D & CAPA Execution: Champion structured problem-solving (8D, 5-Why, Fishbone, FTA) for critical field excursions. Partner cross-functionally with Design Engineering, Manufacturing Quality, and Supplier Quality to drive permanent design-for-reliability (DFR) and design-for-serviceability (DFS) mitigations.
Rapid Field Containment: Define immediate containment protocols, triage criteria, and inspection work instructions for field technicians and customer-support teams during safety-critical or fleet-wide failure events.
Manage FA Lab & External Testing Partners: Oversee internal failure analysis lab equipment (oscilloscopes, thermal imaging, digital microscopy, dynamometers) and coordinate advanced external analytical testing (CT scanning, SEM/EDX, cross-sectioning, metallurgical analysis).
Standardize RMA & Depot FA Workflows: Establish standardized teardown SOPs, failure code taxonomies, and disposition tracking across repair depots and Salem assembly facilities.
Quality Reporting & Pareto Analytics: Analyze fleet return rates, Mean Time Between Incidents (MTBI), and component failure modes to deliver clear Pareto metrics and technical executive summaries to engineering and operations leadership.
About You
Education: Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Systems Engineering, or equivalent practical experience.
Experience: 6+ years of hands-on failure analysis, field quality, or reliability engineering experience supporting complex electromechanical systems (Robotics, Autonomous Vehicles, EV/Powertrain, Aerospace, or Heavy Industrial Automation).
Mechatronics Troubleshooting: Demonstrated ability to trace cross-domain issues spanning mechanical stress/wear, electrical signal degradation, motor drive failures, and firmware/sensor interaction.
Structured RCA Mastery: Practical mastery of 8D, Fault Tree Analysis (FTA), FMEA, and Ishikawa diagrams, with a portfolio of verified corrective actions that eliminated field failure modes.
Lab Tool Proficiency: Proficiency with bench diagnostic tools (DMMs, high-bandwidth oscilloscopes, logic analyzers, optical microscopy, thermal cameras, torque test fixtures).
Preferred Qualifications
Experience with Linux environments, ROS, CAN/EtherCAT protocol analyzers, and cloud-based time-series data visualization (e.g., Grafana, Datadog, or custom fleet dashboards).
Working knowledge of functional safety considerations (ISO 13849, IEC 62061) in industrial automation or mobile robotics.
Proven background managing third-party destructive/non-destructive testing labs (SEM, EDX, X-ray/CT scan).
ASQ certification (CQE, CRE) or Lean Six Sigma Green/Black Belt.
Work Environment & Travel
Based on-site at our Salem, OR facility with regular presence across testing labs, service centers, and assembly lines.
Travel up to 20% to customer logistics centers, field trial sites, or component suppliers for urgent containment and on-site failure characterization.
Location
This is an onsite position at our Salem office.
The final salary offered to a successful candidate will be dependent on several factors that may include but are not limited to: job-related knowledge, skills, and experience. Agility Robotics is a multi-state employer and this salary range may not reflect positions who work in other locations. These ranges may be modified in the future.
Anticipated Base Salary Range
$147,000—$191,000 USD