R&D Senior Hardware Test Engineer The R&D Hardware Test Engineer designs, develops, and implements automated electro-mechanical test systems that accelerate product development, improve reliability, and expand lab testing capability. This role focuses heavily on reliability and life testing, designed experiments (DOE), LabVIEW programming, automated data acquisition, and test fixture development. The engineer partners with mechanical, electrical, and controls engineers to define test strategies, enhance Product Qualification Plans (PQPs), and ensure robust verification and validation of complex pharmacy automation devices - and serves as a technical mentor, coaching junior engineers and test technicians in test methodology, statistical rigor, automation, and data integrity.
Key Responsibilities Reliability & Life Testing - Design and execute reliability, durability, and accelerated life test programs for electro-mechanical subsystems and full systems.
- Define reliability targets and test-to-failure strategies; determine sample sizes, run times, cycle counts, and confidence/reliability levels.
- Build and maintain long-duration life-cycle test stands with automated cycle counting, fault detection, and unattended run capability.
- Perform failure analysis and root cause investigation (FMEA, fault tree, 5-Why, 8D) and translate findings into design and test improvements.
- Apply life data analysis techniques (Weibull, MTBF/MCBF, hazard and survival plots, censored data) to quantify reliability growth and report trends and risks to program teams.
Design of Experiments & Statistical Test Methods - Plan and execute designed experiments (full/fractional factorial, screening, response surface) to characterize system performance and identify critical factors.
- Define factors, levels, responses, blocking, and randomization; plan and execute Measurement System Analysis (MSA), including Gage R&R, to confirm test methods are repeatable and reproducible before running studies.
- Analyze results using ANOVA, regression, capability analysis (Cp/Cpk), and hypothesis testing in Minitab, Python, or JMP.
- Use DOE outputs to set design margins, tolerance windows, and robust operating parameters.
- Automate data aggregation, trending, and reporting so results are reproducible and audit-ready.
Test System Design & Automation - Design electro-mechanical test systems and fixtures to support verification, validation, and reliability testing.
- Develop automated test workflows in LabVIEW including DAQ configuration, control logic, and data handling.
- Build integrated DAQ systems for sensors, motion control, communication technologies, and electro-mechanical devices.
- Improve or develop PLC- and microcontroller-based systems (e.g., DAQ, Arduino, Raspberry Pi platforms).
- Create benchmark programs and automated sequences to reduce machine downtime and accelerate troubleshooting.
Verification, Validation & Test Planning - Review Product Qualification Plans (PQPs) and recommend additional test coverage, automation opportunities, and reliability improvements.
- Partner with mechanical, electrical, and controls engineers to create robust test plans for subsystems and prototypes.
- Perform hands-on test execution when needed, ensuring accurate data capture and traceability.
- Champion statistically sound sampling and acceptance criteria within PQPs and verification protocols.
Mentoring & Technical Leadership - Mentor junior engineers and test technicians in test setup, instrumentation, data integrity, and troubleshooting methodology.
- Coach the team on reliability and statistical concepts - sample size, variation, measurement error, and how to interpret results.
- Develop and deliver cross-training on LabVIEW, DAQ hardware, fixture use, and automated test sequences to broaden lab capability.
- Create clear work instructions, test protocols, and templates that enable technicians to run tests independently and consistently.
- Review test plans, data packages, and reports from others and provide constructive, specific technical feedback.
- Serve as a go-to technical resource during test escalations and support onboarding of new engineers and technicians.
Lab Support & Prototype Development - Increase testing throughput and reduce downtime through parallel test setups, preventative maintenance, and system health monitoring.
- Design and assemble rapid prototypes and test fixtures to evaluate the feasibility of new concepts, including wiring, assembly, and instrumentation setup.
- Commission new test hardware and validate performance before release to the team.
- Troubleshoot complex electro-mechanical and automation issues and contribute to best practices for safety, testing procedures, and ISO-aligned processes.
Qualifications Education - Bachelor's degree in Engineering or a related technical field (Mechanical, Electrical, Mechatronics, Systems, Automation, Physics, Applied Science, etc.).
- Master's degree is a plus. Reliability Engineering certification (CRE), Six Sigma, or DFSS training is a plus.
Experience - Minimum experience of 5 years in a similar role.
- Experience with verification and validation testing.
- Hands-on experience designing automated test systems and fixtures.
- Demonstrated experience planning, executing, and interpreting Measurement System Analysis studies, including Gage R&R, for engineering test methods and equipment.
- Practical experience applying DOE and statistical analysis to characterize hardware performance.
- Strong LabVIEW programming background.
- Experience with computer-controlled electromechanical or networked systems.
- Experience mentoring, coaching, or technically leading engineers or technicians.
Skills & Abilities - Programming or scripting experience with LabVIEW, Python, SQL, or similar tools.
- Experience with DAQ systems (NI hardware and similar), sensors, PLCs, microcontrollers (Arduino), and motion control.
- Statistical analysis proficiency - DOE, ANOVA, regression, Weibull/life data analysis, capability studies, and Gage R&R - using Minitab, Python, or JMP.
- Working knowledge of reliability tools: FMEA, fault tree analysis, root cause methodology, and reliability growth tracking.
- Sound judgment on sample size, test duration, and acceptance criteria, with the ability to defend those choices to stakeholders.
- Ability to design (CAD), assemble, and troubleshoot complex test setups, with strong mechanical and electrical aptitude including sensor selection, signal conditioning, and instrumentation accuracy.
- Ability to teach and coach others - explaining technical and statistical concepts clearly to non-specialists.
Physical Requirements - Requires frequent sitting, standing, and bending.
- Requires occasional stooping and kneeling.
- Ability to safely lift up to 45 pounds unaided.
At BD, we prioritize on-site collaboration because we believe it fosters creativity, innovation, and effective problem-solving, which are essential in the fast-paced healthcare industry. For most roles, we require a minimum of 4 days of in-office presence per week to maintain our culture of excellence and ensure smooth operations, while also recognizing the importance of flexibility and work-life balance. Remote or field-based positions will have different workplace arrangements which will be indicated in the job posting.
For certain roles at BD, employment is contingent upon the Company's receipt of sufficient proof that you are fully vaccinated against COVID-19. In some locations, testing for COVID-19 may be available and/or required. Consistent with BD's Workplace Accommodations Policy, requests for accommodation will be considered pursuant to applicable law.
Primary Work LocationUSA NC - Durham - Roche Drive
Additional LocationsWork Shift 
