Failure Analysis Engineer

*If interested in this role, please contact Kyle McLean at View email address on click.appcast.io*

We are looking to hire a Failure Analysis Engineering Technician/Engineer to play a key role in diagnosing, repairing, and validating complex electronic products from the finished unit down to the component level. This position focuses on end-to-end product troubleshooting, RMA and failure analysis, and technical support for engineering and production teams to ensure reliable, high-quality electronic assemblies and products.

Responsibilities

• Diagnose failures across PCB assemblies, subassemblies, cables and harnesses, mechanical assemblies, box-build products, and finished goods using schematics, drawings, BOMs, test data, RMA information, and other technical documentation.
• Disassemble and tear down finished products as needed to access internal assemblies, reproduce failures, and determine the true failure location.
• Perform component- and circuit-level troubleshooting on SMT and through-hole PCB assemblies to identify electrical, functional, mechanical, connection, workmanship, and assembly defects.
• Perform or oversee component replacement and advanced rework, including BGA, QFN, QFP, fine-pitch rework, soldering, desoldering, jumper installation, trace and pad repair, cable, harness, and PON replacement, connector repair, and other approved repair activities.
• Restore and reassemble repaired products in accordance with approved manufacturing and workmanship requirements, ensuring proper fit, function, and reliability.
• Determine appropriate disposition for failed products, including repair, additional engineering evaluation, return to supplier or customer, or scrap.
• Coordinate retest and final product validation after repair to confirm complete functional recovery prior to release.
• Lead or support technical investigation of RMA and customer-returned products, including failure reproduction, product teardown, repair feasibility assessment, and technical disposition.
• Analyze recurring failures and repair trends across PCBA, subassembly, and finished-product levels to identify root causes and opportunities for design, process, or test improvements.
• Collaborate with Test, Process, Manufacturing, Quality, and customer engineering teams to distinguish product failures from process, test, assembly, or handling issues.
• Participate in root-cause analysis, corrective and preventive actions, 8D investigations, CAPA initiatives, and customer failure investigations as required.
• Support engineering evaluations, prototype builds, new product introduction activities, production launches, and field-return investigations.
• Develop and validate repair, teardown, reassembly, and recovery procedures for recurring failure modes to ensure consistent, high-quality repairs.
• Provide technical direction and support to Production, Quality, Repair Technicians, and other cross-functional teams involved in repair and failure analysis activities.
• Interpret and apply IPC-A-610 Acceptability of Electronic Assemblies requirements and applicable customer workmanship standards during repair and validation.
• Ensure repaired PCBAs, subassemblies, and finished products meet applicable IPC, customer, engineering, mechanical, and internal requirements.
• Verify that disassembly and repair activities do not introduce secondary damage and that products are correctly restored and reassembled.
• Document repair activities, RMA findings, failure modes, root causes, dispositions, and corrective actions thoroughly and accurately.
• Support internal and customer quality audits and provide technical evidence and documentation for product failure investigations.
• Work with Test Engineering to confirm that repaired products successfully complete all applicable functional tests and final-product validation.
• Maintain accurate repair records, RMA reports, failure-analysis reports, defect codes, teardown findings, and engineering documentation.
• Review repair and return data to identify trends and opportunities to reduce repeat failures, scrap, rework, and repair turnaround time.
• Develop and update repair instructions, RMA investigation methods, teardown and reassembly procedures, troubleshooting guides, and standard operating procedures to support continuous improvement.

Essential Skills

• At least 5 years of experience in electronics manufacturing, product repair, failure analysis, RMA investigation, PCBA rework, or electronic troubleshooting.
• Proven experience troubleshooting complete electronic products and advanced SMT packages, from finished-product level down to component and circuit level.
• Strong understanding of electronic products, SMT and PCBA manufacturing, assembly, box-build, and product repair processes.
• Ability to read and interpret schematics, PCB layouts, assembly and mechanical drawings, bills of materials (BOMs), work instructions, test results, and product specifications.
• Hands-on expertise with product teardown and reassembly, soldering, electronic rework, cable and harness repair, connectors, and mechanical integration.
• Ability to use digital multimeters, oscilloscopes, power supplies, and related diagnostic equipment to isolate and verify failures.
• Experience with failure analysis techniques and repair equipment, including component-level testing and troubleshooting.
• Working knowledge of RMA processes, failure analysis testing, and documentation of defect codes, findings, and corrective actions.
• Strong analytical and problem-solving skills with the ability to identify root causes and propose effective corrective and preventive actions.
• Clear and accurate technical communication skills for documenting findings and collaborating with cross-functional teams.

*If interested in this role, please contact Kyle McLean at View email address on click.appcast.io*

This is a Permanent position based out of Plano, TX.

The pay range for this position is $38.50 - $50.00/hr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: Medical, dental & vision Critical Illness, Accident, and Hospital 401(k) Retirement Plan Pre-tax and Roth post-tax contributions available Life Insurance (Voluntary Life & AD&D for the employee and dependents) Short and long-term disability Health Spending Account (HSA) Transportation benefits Employee Assistance Program Time Off/Leave (PTO, Vacation or Sick Leave)

This is a Permanent position based out of Plano, TX.

This position is anticipated to close on Nov 6, 2026.

This is a fully onsite position in Plano,TX.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on click.appcast.io for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.