MGR II QLTY & RELIABILITY ENGINEERING

Job Overview

High-Speed Cable Assembly Products Reliability & Testing Leader - TE Connectivity, Data and Device Networks (DDN)

 ROLE DESCRIPTION

The High-Speed Cable Assembly Reliability & Testing (R&T) Leader will lead a dedicated team of R&T engineers and will have responsibility for driving standardized Design for Reliability Engineering (DfRE) and Robustness Validation (RV) Methodologies for all High-Speed Cable Assembly Products in the DDN Portfolio.  He/she and their team will work extremely closely with customers, Product Development Engineering (PDE) teams, Manufacturing Process Development Engineering (MPDE) teams, Field Application Engineering (FAE) and Advanced Quality Engineering (AQE) to deeply understand the end application requirements and the associated “mission profile”.  They will partner with the Global R&T COE to drive the application of standardized methodologies and alignment on all Reliability Testing and Test & Validation plans for each of the assigned new product development programs.  They will identify unique product line test needs and application testing requirements and work with the R&T COE to develop custom Test System & Software as required to support the unique testing requirements for each product line.  In addition, he/she will also partner with the Global R&T COE to co-develop Reliability Test Plans and Test & Validation Plans aligned with TE’s LeanPD stage gate approach for product development.

The High-Speed Cable Assembly Reliability & Testing (R&T) Leader will oversee integrating reliability considerations during technology & product evaluation, NPI product development from receipt of Customer Spec (“mission profile”) through Product Release into mass production.  DfRE Experts in the Global R&T COE will help determine the appropriate test strategy to collect data using destructive Highly Accelerated Life Test (HALT) or Highly Accelerated Stress Tests (HAST) techniques to evaluate product reliability.  Based on collected data and in close collaboration with PDE teams, they will identify weak design/process features or components and work closely with PDE and AQE on the development of corrective actions and improvement plans, engaging with material and component experts to evaluate improvements of the corrective actions by technics such a stress/accelerated screening.

The High-Speed Cable Assembly Reliability & Testing (R&T) Leader will be instrumental partnering with PDE’s to quickly produce and evaluate first samples to expedite speed to market and drive fast and iterative product design improvements.  They will drive Early Concept Testing identifying potential weaknesses and failure mechanisms in the product design.  They will also work very closely with MPDE about Process Developments and Equipment Developments, developing comprehensive test plans to ensure capability to six sigma standards and driving world-class Simultaneous Engineering (Concurrent Engineering).  They will also support failure analysis (F/A) and Root Cause and Corrective Action (RCCA) of line scrap and customer returns as well as competitive benchmarking activities.

R&T Engineers and DfREs will leverage a reliability approach as defined in structured development approach such as Design for Six Sigma (DFSS), Toyota inspired LPDS methodologies and Robust Design principles, and will master reliability data sources, stress acceleration models, ALT and Test to Failure analysis and other reliability tools in order to drive data and capability based decisions to ensure the reliability and robustness of DDN products meet and/or exceed customer expectations

Job Requirements

ENGINEERS ON HIGH-SPEED CABLE ASSEMBLY PRODUCTS R&T TEAM WILL HAVE THE FOLLOWING RESPONSIBILITIES:

• Integrate reliability considerations during technology & product evaluation, NPI product development from receipt of Customer Spec (Mission Profile) through Product Release into mass production.
• Contribute towards requirement engineering. Understand the load requirements clearly to derive inner load and stresses.
• Drive reliability planning tailored to environmental and use conditions, integrating contingency planning and business impact.
• Analysis of test data. knowledge on data acquisition methods and system.
• Apply accelerated test models and test-to-failure strategies to determine reliability limits and identify failure modes.
• Perform the initial FIT estimation based on data from standards such as Siemens Norm SN-29500.  Calculate final FIT value based on test data.
• Analyze customer requirements, application requirements and mission profile to determine the optimal validation test to evaluate reliability of DDN products.
• Lead corrective and preventive action (CAPA) processes for reliability issues across products.
• Contribute to or manage a centralized database of reliability test plans, models, and field data to promote reuse and faster decision-making.
• Present reliability status and risks to executive leadership, influencing design decisions and investment in robustness.
• Leverage on accelerated test methods to explore design margins and to enable fast selection of concepts.
• Provide guidance on sample size requirements and duration for reliability testing by utilizing reliability statistics.
• Act as a champion for reliability culture, fostering a proactive and metrics-driven mindset within cross-functional teams.
• Analyze data from those optimal validation tests to calculate reliability and identify risks or failures.  Calculate MTTF based on test to failure evaluation.
• For identified risks, support definition of mitigation plans and implementation to improve reliability.
• For identified high risk failure modes and actual failures, support definition of corrective actions and their implementation to improve reliability.
• Communicate and interact with customer reliability experts to report on reliability analysis.
• Participate in design reviews and facilitate the reliability section of the design review.
• Establish a database of reliability tests, models to be re-used across projects.

What your background should look like

YOU MUST HAVE

• Bachelor/ Master’s degree in technical discipline (Electrical Engineering, Electronics, Mechatronics)
• 10+ years of Experience in all aspects of reliability engineering for electronic or mechatronics products from reliability estimation to reliability calculation and risk identification.
• Must also have many years of experience working with test equipment, test systems, test labs, development and deployment of HALT/HAST testing, Test & Validation Plans, development of custom test systems and performing “application tests.”  Must have a good balance between theory and practice.
• Experience interacting with global cross-functional engineering teams in multi-site global organization.
• Excellent English, both verbal and written, and the ability to interact professionally with customers, leadership, stakeholders, cross functional teams and subject matter experts.
• Exceptional analytical, critical thinking, and problem-solving skills and ability to make decisions when presented with a series of challenges, conflicts and constraints.  Ability to drive to big picture goals and milestones while valuing and maintaining strong attention to the details.
• Knowledge on FIT estimation methodology, statistical analysis for reliability calculation such as Weibull-analysis or c2-statistics, application of Bayes theorem, random failure principle, FMEDA, FTA
• Reliability Engineering training from company, ASQ, TUV, Reliasoft or equivalent
• Experience with custom product development, working closely with customers to define mission profile of the end application and optimizing reliability strategy based on customer needs.
• Experience in running statistical analysis for reliability calculation for mechatronic products.
• A high curiosity in understanding how systems/products work along with a reverse engineering mindset.
• Willingness to travel as required, ~20%

WE VALUE

• DFSS Blackbelt or DFSS Green Belt Certified
• Standards Knowledge - EIA-364 1000B, TIA 942, IPC Standards for Interconnecting and Packaging Electronic Assemblies, UL Standards for Data Center Component Level Certifications (i.e. UL 1977, UL 444, UL 817, UL 2416).
• Knowledge in data center architecture, connectors, sockets, wire harnesses, High-Speed connectivity products, electronics, measurement & signal processing.
• Experience in product development for data center applications
• Experience in product development, test & validation of connectors & sockets, High-Speed interconnect solutions.

Competencies