BAE Systems - Principal Reliability Engineer

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. This position offers an excellent opportunity for a recent graduate or early-career professional to gain hands-on experience in a critical engineering discipline, supporting cutting-edge technologies and contributing to national security. You will play a vital role in ensuring the reliability and performance of our systems, working alongside experienced engineers and contributing to continuous improvement. This role is designed for growth, with opportunities to expand your skill set and take on increasing responsibilities as you progress within the company.

The BAE Systems C4ISR team develops and supports a diverse portfolio of technologies vital to modern warfare, integrated into platforms like the F-16, F-18, E-2D, and F-35. Our products include: Electronic Warfare Systems: Systems for detecting, jamming, and protecting against electronic threats; Precision Navigation Systems: High-accuracy positioning, navigation, and timing solutions; Advanced Displays & Processing: Ruggedized displays and computing platforms for harsh environments; and Data Links: Secure and reliable data communication networks. We provide the critical command, control, and intelligence capabilities our customers rely on.

Failure Analysis & FRACAS (Failure Reporting, Analysis, and Corrective Action System)

• Analyze failed hardware and software components from production and field returns to determine root cause of failures and assist in developing corrective actions. This includes understanding failure mechanisms and applying engineering principles to diagnose issues.
• Collaborate with internal teams (Quality, Hardware Design, Manufacturing, Software Engineering) to gather information, facilitate investigations, and implement solutions.
• Interface with Suppliers/Vendors to review their failure analysis findings, ensure alignment, and drive resolution of supplier-related issues.
• Perform detailed failure analysis using a variety of techniques (visual inspection, microscopy, component-level testing, data analysis, and potentially more advanced techniques like X-ray or SEM depending on your product).
• Author clear, concise, and technically accurate customer-facing failure reports and narratives, including recommended corrective actions and clear communication of technical issues.
• Maintain and update the FRACAS database with accurate failure data, analysis results, and corrective action tracking.
• Review and interpret data from manufacturing process monitoring, environmental stress screening (ESS), and system testing to identify potential reliability concerns.
• Collaborate with test teams to investigate failure modes, refine test procedures, and improve test coverage.

Reliability Data Analysis & Prediction

• Collect, analyze, and interpret reliability data from various sources (field failures, testing, simulations) to identify trends, potential areas for improvement, and quantify product reliability.
• Utilize statistical tools and techniques (Weibull analysis, MTBF/MTTR calculations, FMECA, Root Cause Analysis, hypothesis testing) to assess system reliability and predict future performance.
• Develop and maintain reliability prediction models to assess design margins and optimize product life.
• Perform Reliability Growth Analysis to track improvement over time.
• Contribute to the development of reliability test plans and strategies.

Maintainability & Testability Analysis

• Perform Maintainability analysis, estimate Mean Time To Repair (MTTR), and identify opportunities to improve product serviceability.
• Perform system-level testability analysis and demonstrate the effectiveness of diagnostic features.
• Support the development and implementation of diagnostic procedures to facilitate efficient troubleshooting.

Process Improvement & Quality Assurance

• Identify opportunities to improve manufacturing processes, design practices, and quality control procedures to reduce failure rates and enhance product reliability.
• Contribute to the development and implementation of corrective and preventative actions (CAPA).
• Participate in Design for Reliability (DFR) and Design for Manufacturability (DFM) reviews.
• Lead small-scale reliability improvement projects.

Documentation & Reporting

• Create and maintain detailed documentation of failure analysis results, test procedures, reliability data, and analysis reports.
• Prepare and deliver presentations summarizing reliability findings for internal stakeholders (engineering teams, management) and potentially external stakeholders (customers, vendors).

• Bachelor's degree in engineering (Electrical, Mechanical, Aerospace, Systems, or related field) with at least 6 years of experience (4 years with a Masters degree)
• Strong analytical and problem-solving skills.
• Excellent written and verbal communication skills.
• Proficiency in Microsoft Office Suite (Excel, Word, PowerPoint).
• Ability to work independently and as part of a team.
• Ability to obtain/maintain a security clearance.
• Lead reliability science initiatives, including failure analysis, proposal development, and program status management. Proven ability to lead cross-functional teams.

• Experience with failure analysis techniques (e.g., visual inspection, microscopy, X-ray, electrical testing).
• Familiarity with reliability standards (e.g., MIL-STD-883, MIL-STD-750, MIL-HDBK-217, MIL-STD-1629A, MIL-STD-454, MIL-STD-470, and MIL-HDBK-472).
• Knowledge of statistical analysis tools (e.g., Minitab, JMP).
• Experience with FRACAS databases and reporting systems, Reliability Testing, Fault Tree Analysis (FTA), and Reliability/Maintainability Modeling including Availability.
• Experience with electronic circuits and components.
• Understanding of manufacturing processes.
• Experience with Python or other scripting languages for data analysis.

Full-Time Salary Range: $128831 - $219012

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.


BAE Systems, Inc. is the U.S. subsidiary of BAE Systems plc, an international defense, aerospace and security company which delivers a full range of products and services for air, land and naval forces, as well as advanced electronics, security, information technology solutions and customer support services. Improving the future and protecting lives is an ambitious mission, but it's what we do at BAE Systems. Working here means using your passion and ingenuity where it counts - defending national security with breakthrough technology, superior products, and intelligence solutions. As you develop the latest technology and defend national security, you will continually hone your skills on a team-making a big impact on a global scale. At BAE Systems, you'll find a rewarding career that truly makes a difference. Electronic Systems (ES) is the global innovator behind BAE Systems' game-changing defense and commercial electronics. Exploiting every electron, we push the limits of what is possible, giving our customers the edge and our employees opportunities to change the world. Our products and capabilities can be found everywhere - from the depths of the ocean to the far reaches of space. At our core are more than 14,000 highly talented Electronic Systems employees with the brightest minds in the industry, we make an impact - for our customers and the communities we serve.

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.