Lead Mechanical Design Engineer - Reliability Engineering

LEAD MEACHANICAL DESIGN ENGINEER- DESIGN FOR RELIABILTY At TE, you will unleash your potential working with people from diverse backgrounds and industries to create a safer, sustainable and more connected world. Job Overview Design and drive reliability engineering activities for TE Sensor Products throughout the product development lifecycle, ensuring products meet customer reliability, durability, safety, and mission profile requirements. Define reliability strategies, validation approaches, failure analysis methods, and reliability risk mitigation plans for automotive sensor products from concept through production. KEY RESPONSBILITIES: Minimum 7+ years of experience in reliability engineering for automotive electronic, sensor, or mechatronic products. Strong experience in reliability prediction, reliability testing, reliability calculations, and risk identification. Expertise in FIT rate estimation methodologies and statistical reliability analysis including Weibull analysis, χ²-statistics, Bayes theorem, random failure principles, FMEDA, and FTA. Develop and execute Design for Reliability (DfR) methodologies for TE Sensor products used in Automotive, Industrial, Medical, AD&M (Aerospace, Defense & Marine), and other business domains. Define reliability requirements based on customer specifications, mission profiles, application conditions, and product architecture. Perform reliability prediction, FIT rate estimation, MTTF calculation, and reliability risk assessment using industry standards and test data. Define reliability validation strategies including HALT, HAST, ALT, Test-to-Failure, accelerated stress testing, and environmental validation. Conduct reliability analyses including Weibull analysis, Chi-square statistics, Bayes theorem application, FMEDA, FTA, and failure mechanism assessments. Analyze validation and field-return data to identify reliability risks, failure modes, and opportunities for product improvement. Support Design of Experiments (DOE) to evaluate alternative materials, manufacturing processes, and design concepts. Collaborate with design, validation, quality, manufacturing, and supplier teams to improve product reliability and robustness. Participate in product design reviews and provide reliability assessments, recommendations, and risk mitigation plans. Develop reliability design guidelines, lessons learned, and best practices for sensor product development. Build and maintain reliability databases including failure mechanisms, test results, acceleration models, and field reliability data. Support supplier selection and qualification activities from a reliability perspective. Contribute to requirement engineering, system understanding, load analysis, and stress derivation activities. Assess and communicate reliability risk throughout all project phases and drive closure of critical risks before SOP. Partner with Quality and Failure Analysis teams to ensure continuous improvement through effective lessons learned implementation. Support Functional Safety and/or AD&M-related reliability activities as required. Comply with processes and best practices for Reliability Engineering and Product Development. DESIRED SKILLS: DFSS, or Six Sigma Black Belt Certified Functional Safety (FuSa) Knowledge and Expertise Standards Knowledge: ISO 16750, IEC 60068, IATF 16949, AS9100 (EN 9100), ISO 9001, AEC-Q100, ISO 13485, IEC 60601, DO-160, and MIL-STD-810. Solid knowledge in sensors electronics, measurement & signal processing. Willingness to travel to other TE locations, customers, and suppliers. Experience in sensor product development for automotive application Ability to develop your own engineering tools (like python) Good written and spoken English and communication skills. What your background should look like Master's Degree or equivalent in Reliability Engineering, Electrical Engineering, Electronics, Mechatronics, Mechanical Engineering, or related technical discipline. Minimum 7+ years of experience in reliability engineering for automotive electronic, sensor, or mechatronic products. Strong experience in reliability prediction, reliability testing, reliability calculations, and risk identification. Competencies Values: Integrity, Accountability, Inclusion, Innovation, Teamwork Experience Level Senior Level