The Product Reliability Engineer will focus on improving product reliability, durability, and field performance of Royal Switchgear products. Lead design and execution of product-level reliability tests, develop test apparatus, analyze failure modes, and drive design improvements to reduce field failures and warranty costs.
Key Responsibilities
- Lead product reliability strategy: set reliability targets, perform FMEA, Weibull and life-data analysis (MTBF/MTTR) for switchgear products and components.
- Design test programs for components and complete assemblies (HALT/HASS, accelerated life test, thermal cycling, vibration, electrical endurance, dielectric/insulation tests).
- Specify, design, and build custom test apparatus, fixtures, and jigs required to replicate field stresses and validation scenarios.
- Set up, commission, and operate test rigs and instrumentation (data acquisition, environmental chambers, power supplies, relays, load banks).
- Develop test procedures, protocols, and pass/fail criteria; ensure repeatability, traceability, and calibration of test equipment.
- Execute tests, capture and analyze test data, produce detailed test reports, and translate findings into actionable design changes.
- Lead root-cause analysis on product failures and field returns; recommend design, material, or process changes and verify fixes via testing.
- Collaborate closely with design engineering, product validation, and manufacturing to incorporate DfR/DfM practices and plan design verification.
- Maintain reliability documentation: test plans, life-cycle predictions, reliability databases, and validation evidence for product sign-off.
- Support new product introduction with reliability verification, test campaigns, and acceptance criteria.
- Train engineering and lab technicians on test setups, safety, and data collection best practices.
- Manage external test labs and vendor testing when needed; oversee third-party test contracts and coordinate sample logistics.
Required Qualifications
- Bachelor's degree in Electrical, Mechanical, Reliability Engineering, or related discipline.
- 3+ years' experience in product reliability, test engineering, or design validation-preferably with switchgear, breakers, relays, or power distribution equipment.
- Proven experience designing test apparatus, fixtures, and setting up/operating reliability test rigs.
- Strong knowledge of reliability methods (FMEA, RCM, Weibull), environmental and electrical testing standards.
- Hands-on proficiency with data acquisition systems, instrumentation, environmental chambers, and test automation.
- Ability to interpret electrical/mechanical drawings, specify components, and prototype fixtures.
- Strong analytical skills (Excel, Minitab, or equivalent) and experience writing clear test reports.
- Excellent communication and cross-functional collaboration skills.
Preferred
- Experience with HALT/HASS, accelerated aging, and accelerated life test design.
- Familiarity with relevant standards (IEC, IEEE) for switchgear and insulation testing.
- Experience with LabVIEW, Python, or test automation tools.
- Six Sigma or reliability-centered maintenance exposure.
