Senior Failure Analysis Engineer – Mechanical

Location: Onsite at our Ontario, CA office location

About the Role：

We are seeking an experienced Senior Failure Analysis Engineer – Mechanical to lead failure analysis of returned products (RMA), with a focus on mechanical, structural, and materials-related failures across our global product portfolio.

In this role, you will perform in-depth physical and component-level failure analysis to identify the root causes of complex product failures. You will leverage mechanical inspection, dimensional and tolerance analysis, stress and fracture analysis, leak testing, metallography, SEM/EDS, non-destructive testing, and other analytical techniques to diagnose failures and translate findings into actionable improvements across product design, manufacturing processes, and material/component quality. You will work closely with R&D, Quality, Manufacturing, Supplier Quality, and other cross-functional teams globally to drive issues through resolution. You will also contribute to the development of our failure analysis knowledge base and AI-enabled diagnostic capabilities by transforming engineering expertise and historical failure data into scalable diagnostic methodologies and structured knowledge.

Key Responsibilities：

1. Failure Analysis & Root Cause Investigation:

* Own technical failure analysis of RMA products involving mechanical, structural, and materials-related issues, driving investigations from initial diagnosis through root-cause identification and closure.

* Perform product teardown and component-level physical diagnostics to identify failure mechanisms and determine root causes.

* Conduct mechanical and structural investigations using techniques such as dimensional and tolerance analysis, stress/fatigue analysis, leak and sealing integrity testing, fracture analysis, metallography, and non-destructive testing (NDT).

* Perform or interpret advanced material characterization and fracture analysis, including Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray Spectroscopy (EDS), and metallographic analysis, as applicable.

* Investigate failures related to mechanical design, manufacturing processes, assembly, materials, interfaces, sealing systems, and environmental or usage conditions.

* Apply structured root cause analysis methodologies to distinguish among design-, manufacturing-, material/component-, and use-related failure mechanisms and recommend appropriate corrective and preventive actions.

* Execute failure investigations in accordance with established 8D methodologies, including D4 root-cause analysis and verification at the component level.

* Support established turnaround targets for initial assessment, in-depth analysis, root-cause identification, and issue closure.

2. Cross-Functional Engineering Collaboration:

* Partner closely with R&D, Quality, Manufacturing, Supplier Quality, and other engineering teams to translate failure analysis findings into improvements in product design, manufacturing processes, assembly methods, and material/component quality.

* Provide technical data, physical evidence, and engineering analysis to support corrective actions and long-term product quality improvements.

* Participate in recurring technical reviews with globally distributed engineering and quality teams, ensuring that failure symptoms, investigative findings, root causes, and recommended actions are communicated accurately and systematically.

* Drive complex technical issues across functional and geographic boundaries through investigation and resolution.

3.Technical Documentation & Continuous Improvement:

* Develop comprehensive and standardized failure analysis reports, including technical reports in English, documenting failure symptoms, investigative methods, physical evidence, root causes, and recommended corrective actions.

* Capture recurring mechanical and structural failure modes, root causes, and corrective actions to continuously improve internal failure analysis methodologies and knowledge repositories.

* Contribute to the development and maintenance of failure case libraries, root-cause databases, diagnostic standards, and engineering best practices.

* Help establish consistent criteria for classifying product failures, including distinctions among design, manufacturing, material/component, and use-related causes.

* Support the development of AI-enabled failure analysis tools and diagnostic agents by translating mechanical and materials failure expertise, failure patterns, and diagnostic logic into structured rules and knowledge that can be leveraged by AI systems.

* Identify opportunities to improve failure analysis efficiency, diagnostic accuracy, and overall issue-resolution processes.

Basic Qualifications:

* Bachelor's degree in Mechanical Engineering, Materials Science & Engineering, Materials Engineering, or a related technical discipline; Master's degree preferred.

* 5+ years of professional experience in mechanical, structural, materials, or product failure analysis, reliability engineering, product quality engineering, or a closely related field.

* Demonstrated ability to independently perform component-level failure analysis, identify complex root causes, and develop technically sound corrective action recommendations.

* Strong knowledge of mechanical and structural failure mechanisms, including fracture, fatigue, deformation, wear, material degradation, assembly/process-related defects, sealing failures, and tolerance-related issues.

* Hands-on experience with failure analysis and material characterization techniques such as SEM/EDS, metallography, mechanical property testing, non-destructive testing (NDT), dimensional inspection, and leak/sealing integrity testing.

* Strong understanding of manufacturing processes, mechanical interfaces, tolerance stack-up, material behavior, and their relationship to product reliability and failure mechanisms.

* Strong knowledge of structured root cause analysis methodologies, including 5 Whys, Fault Tree Analysis (FTA), Fishbone/Ishikawa analysis, and Design of Experiments (DOE).

* Experience developing 8D reports and managing corrective and preventive actions (CAPA) through closure.

* Strong technical communication and documentation skills, including the ability to independently prepare detailed failure analysis reports in English.

* Ability to collaborate effectively with globally distributed engineering teams.

Preferred Qualifications:

* 8+ years of experience performing mechanical or materials failure analysis for consumer electronics, IoT devices, smart hardware, or other high-volume manufactured products.

* Experience developing or standardizing mechanical failure analysis methodologies, diagnostic standards, design guidelines, or failure-classification criteria.

* Experience building or maintaining failure case databases, engineering knowledge bases, or structured root-cause repositories.

* Experience applying AI, machine learning, knowledge systems, or AI-assisted diagnostic tools to engineering or failure analysis workflows.

* Demonstrated experience independently leading complex cross-functional failure investigations or engineering projects.

* Previous technical leadership, mentoring, or team leadership experience is a plus.

Global Collaboration:

This role works closely with engineering and quality teams across multiple regions, including teams based in China. Some flexibility for cross-time-zone collaboration is required, including approximately two evening virtual meetings per week, depending on business and project needs.

We strive to schedule cross-regional collaboration thoughtfully and provide reasonable flexibility around working hours when evening meetings are required.

Perks of Benefits:

Our company benefits are designed to convey company culture and values, to create an efficient and inspiring work environment, and to support our employees to give their best in both work and life. We offer the following benefits to eligible employees:

- 10 Days Company Recognized Holidays

- Paid time Off - up to 15 Days

- 401(k) and company match

- Medical & Dental & Vision Insurance Coverage

- Donation Match

- Employee Assistant Program

【For Pay Transparency】Compensation Description

The base salary range for this position in the selected city is $85,000 - $120,000 annually.

Compensation may vary outside of this range depending on a number of factors, including a candidate’s qualifications, skills, competencies and experience, and location. Base pay is one part of the Total Package that is provided to compensate and recognize employees for their work, and this role may be eligible for additional discretionary bonuses/ incentives/ restricted stock units.

Anker Innovations is committed to a diverse and inclusive workplace. Anker Innovations is an equal opportunity employer and does not discriminate on the basis of race, national origin, gender, gender identity, sexual orientation, protected veteran status, disability, age, or other legally protected status. Please contact hr-recruit@anker-in.com if you have any questions.