Senior Failure Analysis & Sustainment Engineer

Forterra

$140K — $185K *
Aerospace & Defense
5 - 7 years of experience
Job Overview by Ladders

Qualifications

  • Bachelor's degree in Mechanical Engineering or related field (advanced degree a plus)
  • 5+ years of experience in mechanical systems engineering, failure analysis, or reliability engineering
  • Hands-on experience troubleshooting mechanical and electromechanical systems
  • Strong root cause analysis skills and familiarity with structured problem-solving methods
  • Experience working cross-functionally in product development or operations environments

Responsibilities

  • Own and build failure analysis processes to improve product support
  • Lead investigations and root cause analysis (RCA) for discrepancy reports
  • Serve as technical authority for product failures, providing guidance to technicians
  • Collaborate cross-functionally with teams in design, manufacturing, and reliability engineering
  • Drive reliability and sustainment initiatives to enhance product lifecycle performance
  • Support engineering changes and manage obsolescence by sourcing replacement parts
  • Enable predictive maintenance capabilities through data analysis

Benefits

  • On-site position in Clarksburg, MD
  • Opportunities for continuous improvement and process development
  • High level of cross-functional collaboration and teamwork
  • Involvement in mission-critical systems and projects
  • Potential for career advancement in a startup environment
Full Job Description
What You'll Do

The Technical Product Support Manager serves as the central technical point of contact for the comprehensive lifecycle support of fielded products. This role ensures sustained operational readiness, drives continuous improvement, and bridges cross-functional teams-including engineering, supply chain, program management, and field service-to deliver seamless product support for both customers and internal stakeholders.

  • Own and build failure analysis processes
    • Establish, implement, and continuously improve processes for identifying, documenting, and quantifying failure modes
    • Lead and manage FRACAS data workflows and ensure high-quality reliability data capture
    • Translate failure data into actionable product and process improvements that enhance system uptime
  • Lead investigations and root cause analysis (RCA)
    • Drive discrepancy report investigations from intake through resolution
    • Perform hands-on forensic analysis of failed components and systems
    • Determine root cause using structured methodologies (e.g., 5 Whys, fishbone, fault tree)
  • Serve as technical authority for product failures
    • Act as SME supporting refurbishment and inspection technicians
    • Provide engineering guidance for troubleshooting, repair decisions, and escalation
    • Interface with design, manufacturing, and reliability teams to close the loop on issues impacting mission-critical systems
  • Cross-functional collaboration
    • Work closely with product design, manufacturing, sustainment logistics, program teams, customer success, and reliability engineering
    • Communicate findings clearly to both technical and non-technical stakeholders
  • Drive reliability and sustainment initiatives
    • Identify trends and systemic issues across fielded systems
    • Lead initiatives to improve product durability, maintainability, and lifecycle performance for mission-critical applications
  • Support engineering changes and obsolescence management
    • Source, test, qualify, and implement replacement parts
    • Contribute to design updates driven by reliability, availability, and maintainability (RAM) objectives
  • Enable predictive maintenance capabilities
    • Analyze correlations between hardware failures and internal system data
    • Develop frameworks for predictive failure modeling and condition-based maintenance to improve uptime
  • Startup Environment
    • Highly self-directed, ownership-driven mindset
    • Comfortable working hands-on with hardware and data
    • Strong analytical and investigative instincts
    • Ability to operate effectively in a fast-paced, evolving environment
    • Clear communicator who can bridge engineering and operations


Minimum Qualifications

  • Bachelor's degree in Mechanical Engineering or related field (advanced degree a plus)
  • 5+ years of experience in mechanical systems engineering, failure analysis, or reliability engineering
  • Hands-on experience troubleshooting mechanical and electromechanical systems
  • Strong root cause analysis skills and familiarity with structured problem-solving methods
  • Experience working cross-functionally in product development or operations environments


Preferred Qualifications

  • Experience with FRACAS systems and reliability data analysis
  • Background in forensic engineering or failure investigation
  • Familiarity with autonomous systems, robotics, or complex electromechanical products
  • Experience with test design, validation, and qualification processes
  • Working knowledge of electrical systems and diagnostics


US Salary Range

$140,000 - $185,000

Location

Clarksburg, MD - On-Site

CLEARANCE ELIGIBILITY - This position may require eligibility to obtain and maintain a U.S. security clearance. For more information about U.S. Security Clearances: click here.

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