Sr. Systems Reliability Engineer
Zone 5 Technologies · United States · $148,000–$180,000 (stated in the posting)
At Zone 5 Technologies, we're redefining what's possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting-edge autonomous solutions that push the boundaries of UAS technology - solving complex challenges that matter.
We're building the future of UAS capabilities, and we're looking for exceptional talent to join us. If you're driven by hard problems, energized by rapid innovation, and ready to make an impact on next-generation flight systems, you belong here.
We are seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle. This role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. You will engage directly with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews.
Key Responsibilities:
Reliability & Maintainability Architecture
- Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C (Reliability, Availability, Maintainability-Cost) Rationale Report
- Lead Failure Modes, Effects, and Criticality Analysis (FMEA/FMECA), Fault Tree Analysis (FTA), and Reliability Block Diagram (RBD) development across system architecture
- Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support R&M requirements analysis and trade studies
- Draft Reliability Predictions (per MIL-HDBK-217 and related methods) and Maintainability Analyses; maintain traceability between R&M requirements, predictions, and demonstrated performance
- Lead Reliability-Centered Maintenance (RCM) and Level of Repair Analysis (LORA); support Testability and Built-In Test (BIT) analysis
Data, Documentation & Test Planning
- Establish and own the Failure Reporting, Analysis, and Corrective Action System (FRACAS); maintain closed-loop failure data collection and trending from design through test, production, and sustainment
- Develop Failure Definitions and Scoring Criteria (FDSC) and reliability test plans tied to program milestones
- Lead reliability growth planning and execution of reliability growth and demonstration testing, including Environmental Stress Screening (ESS) and HALT/HASS where applicable
- Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments
- Develop technical documentation including R&M standards, specifications, procedures, and user guides
- Review ground test, flight test, and live-fire test data to confirm R&M requirements compliance
Customer Engagement & Reviews
- Serve as primary point of contact with customers on R&M matters
- Present R&M analyses, RAM-C Rationale Report updates, and risk posture at Milestone Reviews (A/B/C) and design reviews (PDR, CDR, TRR, PRR)
- Lead Reliability Scoring Conferences and Corrective Action Boards (CAB) with customer participation
- Coordinate responses to customer R&M data item deliverables and support In-Service Reviews
Risk Management & Process Improvement
- Lead Root Cause and Corrective Action (RCCA) investigations for failures identified through FRACAS
- Host corrective action reviews and ensure lessons learned are implemented across the program
- Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence and shelf-life and aging surveillance considerations
- Apply digital engineering and AI-enabled tools (predictive maintenance, digital twins, automated FRACAS analytics) to R&M processes
- Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards
Basic Qualifications:
- 7+ years as a Reliability Engineer, R&M Engineer, or equivalent reliability-critical engineering role
- Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics
- Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards
- Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure
- Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening
- Experience engaging with customers on R&M reviews and milestone/design reviews (PDR, CDR, Milestone B/C)
- Strong system architecture knowledge and R&M requirements decomposition and allocation
- Extensive FMEA/FMECA, FTA, and RBD experience
- Failure investigation with proven corrective action implementation
- Technical writing for R&M program plans, rationale reports, procedures, and documentation
- Design review experience (PDR, CDR, MRR) with strong presentation skills
- Data collection, analysis, and trending for R&M metrics
- U.S. Citizenship
Preferred Qualifications:
- Master's degree in engineering or related field
- 10+ years progressive R&M experience
- ASQ Certified Reliability Engineer (CRE) or equivalent certification
- DoD or Navy R&M programs experience, aligned with SECNAV Reliability and Maintainability Engineering guidance
- Quantitative reliability growth modeling (e.g., Crow-AMSAA) and Weibull analysis
- Maintainability, Testability/BIT, LORA, and RCM experience
- Missile, hypersonic, or munitions systems experience, including all-up-round reliability, environmental stress screening, and shelf-life/stockpile surveillance programs
- Digital engineering and AI-enabled R&M tools (predictive maintenance, digital twins, automated FRACAS analytics)
- Active U.S. Security Clearance or ability to obtain
Level IV - $148k - $180k
Level V - $180k - $219k
What's in it for you:
Benefits:
- Competitive total compensation package
- Comprehensive benefit package options include medical, dental, vision, life, and more.
- 401k with company-match
- 3 weeks of paid time off each year
- 40 hours of sick time
- 12 annual company holidays
Why Join Zone 5 Technologies?
- Innovative Environment: Work on cutting-edge technology that is shaping the future of defense and aerospace.
- Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what’s possible.
- Career Growth: Opportunities for professional development and career advancement.
If you are passionate about unmanned aircraft technology and want to be a part of a dynamic and growing company, we would love to hear from you. Apply today and join the Zone 5 Technologies team!
In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.
Zone 5 Technologies is a federal contractor and participates in E-Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E-Verify system. Learn more about your rights and responsibilities under E-Verify: https://www.e-verify.gov.