Senior Principal Reliability Engineer

Job Description BAE Systems is a leading global defense, security, and aerospace company. We deliver a full range of products and services for air, land and naval forces, as well as advanced electronics, information technology solutions, and cyber security. We are experiencing significant growth, driven by innovation and a commitment to supporting our customers. Join us and be a part of something bigger!

We are seeking a motivated and detail-oriented Reliability Engineer to join our dynamic C4ISR (Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance) Systems team.

Responsibilities:

• Lead Failure Analysis & FRACAS (Failure Reporting, Analysis, and Corrective Action System): Serve as a technical leader for all failure analysis activities.
• Independently conduct and lead complex failure investigations on hardware, software, and system-level failures, identifying root causes and recommending comprehensive corrective actions.
• Mentor and guide other engineers in effective failure analysis techniques.
• Collaborate extensively with cross-functional teams (Quality, HW/SW Design, Manufacturing, Test) to drive resolution of failure investigations.
• Directly interface with Suppliers/Vendors to review and validate their failure analysis findings and drive accountability for resolution.
• Utilize advanced failure analysis techniques (e.g., SEM/EDS, X-ray, acoustic microscopy, advanced electrical characterization) to characterize failure mechanisms.
• Author authoritative and customer-facing failure reports, including detailed root cause analysis, corrective action recommendations, and risk assessments.
• Manage and optimize the FRACAS database, ensuring data accuracy, accessibility, and effective trend analysis for proactive reliability improvement.
• Analyze data from manufacturing process monitoring, Environmental Stress Screening (ESS), and system testing to identify potential reliability concerns.

Advanced Reliability Data Analysis & Modeling:

• Lead the collection, analysis, and interpretation of complex reliability data to identify critical trends and predict future failures.
• Develop and apply advanced statistical modeling techniques (e.g., Weibull analysis, Accelerated Life Testing (ALT), Fault Tree Analysis (FTA), Reliability Block Diagrams) to assess system reliability and identify areas for improvement.
• Develop and maintain detailed reliability prediction models, incorporating design margins and field performance data.
• Conduct and document reliability growth analyses.

Proactive Reliability & Maintainability Engineering and Process Improvement:

• Proactively identify opportunities to improve product designs, manufacturing processes, and testing methodologies to enhance reliability, maintainability, testability and reduce costs.
• Lead the development and implementation of robust corrective and preventative actions (CAPA) based on failure analysis and reliability data.
• Drive the implementation of Design for Reliability (DFR) principles throughout the product lifecycle.
• Contribute to the development and maintenance of comprehensive quality control procedures and reliability assurance plans. Technical Leadership & Documentation:
• Serve as a subject matter expert (SME) on reliability engineering principles and best practices.
• Create and deliver technical presentations and reports summarizing reliability findings, trends, and recommendations to internal and external stakeholders, including program management and customers.
• Develop and maintain detailed documentation of failure analysis results, reliability models, and test procedures.

Required Education, Experience, & Skills

• Bachelor’s degree in Engineering (Electrical, Mechanical, Aerospace, Systems, or related field) and a minimum of 8 years of progressive experience in a Reliability Engineering role. Master’s Degree preferred.
• Demonstrated expertise in root cause analysis, failure modes and effects analysis (FMEA), and reliability prediction methods.
• Strong analytical and problem-solving skills with a solid understanding of statistical analysis and data modeling.
• Excellent written and verbal communication skills, including the ability to present complex technical information effectively to diverse audiences.
• Proficiency in Microsoft Office Suite (Excel, Word, PowerPoint).
• Ability to work independently and lead cross-functional teams.
• Ability to obtain/maintain a security clearance.

Preferred Education, Experience, & Skills

• Extensive experience with advanced failure analysis tools and techniques (e.g., SEM/EDS, X-ray, acoustic microscopy, thermal imaging).
• In-depth knowledge of relevant reliability testing standards (e.g., MIL-STD-883, MIL-STD-750, MIL-HDBK-217, MIL-STD-1629A, JEDEC standards).
• Proficiency in statistical analysis software (e.g., Minitab, JMP, R).
• Proven experience with FRACAS databases and reporting systems (e.g., SAP, Teamcenter, Windchill).
• Strong understanding of electronic circuits, components, and materials science.
• Experience with scripting languages (e.g., Python, MATLAB) for data analysis and automation.
• Experience with reliability growth modeling and statistical process control (SPC).
• Experience with DO-254 or similar safety-critical system development standards.

Pay Information Full-Time Salary Range: $132962 - $226035

Please note: This range is based on our market pay structures. However, individual salaries are determined by a variety of factors including, but not limited to: business considerations, local market conditions, and internal equity, as well as candidate qualifications, such as skills, education, and experience.

Employee Benefits: At BAE Systems, we support our employees in all aspects of their life, including their health and financial well-being. Regular employees scheduled to work 20+ hours per week are offered: health, dental, and vision insurance; health savings accounts; a 401(k) savings plan; disability coverage; and life and accident insurance. We also have an employee assistance program, a legal plan, and other perks including discounts on things like home, auto, and pet insurance. Our leave programs include paid time off, paid holidays, as well as other types of leave, including paid parental, military, bereavement, and any applicable federal and state sick leave. Employees may participate in the company recognition program to receive monetary or non-monetary recognition awards. Other incentives may be available based on position level and/or job specifics. About BAE Systems, Inc.BAE Systems, Inc. is a defense, aerospace, and security company headquartered in Falls Church, Virginia, with more than 40,000 employees worldwide. We serve, supply, and protect those who protect us. As one of the most geographically diverse international defense companies, we deliver a full range of products and services spanning air, land, maritime, space, and cyber, including advanced electronics, intelligence solutions, and dedicated customer support.

Our culture is performance-driven and values-led, built on curiosity, creativity, and collaboration. Purpose isn't a tagline here. It's what drives us. We're developing breakthrough technologies that defend national security and make a lasting impact on our communities and our planet. When you join BAE Systems, you're not just building a career. You're contributing to a mission that truly matters.

This position will be posted for at least 5 calendar days. The posting will remain active until the position is filled, or a qualified pool of candidates is identified.