Failure Analysis Engineer Req number: R8486 Employment type: Full time Worksite flexibility: Onsite Who we are CAI is a global services firm with over 9,000 associates worldwide and a yearly revenue of $1.3 billion+. We have over 40 years of excellence in uniting talent and technology to power the possible for our clients, colleagues, and communities. As a privately held company, we have the freedom and focus to do what is right—whatever it takes.
Our tailor-made solutions create lasting results across the public and commercial sectors, and we are trailblazers in bringing neurodiversity to the enterprise. Job Summary We are looking for a motivated Failure Analysis Engineer ready to take us to the next level! If you have materials engineering expertise, hands-on failure analysis experience, and strong problem-solving skills, and are looking for your next career move, apply now.
Job Description We are looking for a Failure Analysis Engineer to be a crucial member of the Failure Analysis and Engineering team responsible for investigating product failures, manufacturing issues, customer complaints, and field returns. This position will be Full-Time and On-Site in Hampton, VA. Export Control Requirement This position involves access to information and hardware subject to the International Traffic in Arms Regulations (ITAR) and/or Export Administration Regulations (EAR).
Candidates must be a U.S. Person as defined by ITAR (U.S. citizen, U.S. permanent resident, or protected individual). What You’ll Do Perform failure analysis on customer returns, warranty claims, manufacturing defects, reliability failures, and field returns Conduct non-destructive and destructive analysis to determine failure modes and mechanisms Utilize analytical techniques, including microscopy, cross-section analysis, material characterization, X-ray inspection, and SEM/EDS Prepare samples and perform laboratory investigations according to established procedures and best practices Generate clear and concise technical reports documenting observations, findings, conclusions, and recommendations Support root cause investigations using structured methodologies such as 8D, 5 Why, Fishbone, Fault Tree Analysis (FTA), and/or Red X Collaborate with Product Engineering, Manufacturing Engineering, Quality Engineering, and Operations teams to resolve complex technical issues Participate in customer complaint investigations and provide technical evidence supporting corrective and preventive actions Support manufacturing sites in resolving scrap, yield, process, and field reliability issues Analyze trends in failure data and identify recurring failure mechanisms or systemic issues Contribute to product reliability improvements through understanding failure mechanisms and risk reduction recommendations Support DFMEA, PFMEA, and Lessons Learned activities through technical findings Maintain records, analysis reports, and documentation in compliance with applicable quality management system requirements Participate in continuous improvement initiatives focused on quality, reliability, cost reduction, and customer satisfaction Work effectively in a cross-functional and global environment supporting multiple manufacturing sites and business units What You'll Need Required: B.S.
degree in Materials Engineering, Mechanical Engineering, Electrical Engineering, Physics, Chemistry, or related technical field Minimum 3-5 years of experience in Failure Analysis, Materials Engineering, Reliability Engineering, Product Engineering, Quality Engineering, or related technical discipline Hands-on experience performing root cause investigations and failure analysis activities Knowledge of analytical and laboratory techniques such as microscopy, metallography, cross-sectioning, SEM/EDS, X-ray, FTIR, DSC, or related methods Strong understanding of engineering problem-solving methodologies including 8D, 5 Why, Fishbone, and Fault Tree Analysis Experience supporting customer complaint inv