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Reliability and Maintainability Engineer (R5301)

Shield AI· Aircraft Operations Division – Customer Operations
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Dallas, TX$117k - $176kFull Time EmployeePosted 3mo ago

About the role

Senior-level Reliability and Maintainability Engineer focused on investigation, root cause analysis, corrective action, and reliability improvement for V-BAT field failures and complex technical issues. Partners across multiple functions to ensure field issues are understood, contained, corrected, and prevented from recurring.

Responsibilities

  • Lead engineering investigations for V-BAT field failures, repeat defects, reliability issues, maintainability issues, and complex technical escalations
  • Drive Root Cause and Corrective Action investigations for fielded V-BAT issues, including containment, root cause identification, corrective action planning, verification, and closure
  • Reproduce and analyze field issues using logs, returned hardware, test data, maintenance records, operational context, configuration data, environmental conditions, and customer-reported symptoms
  • Partner with Fleet Support Engineers, Product Engineering, Quality, Manufacturing, Reliability Data Engineering, Supply Chain, and Operations to investigate and resolve fielded system issues
  • Determine whether issues are caused by design, manufacturing, supplier quality, configuration, software, operator use, environmental exposure, maintenance practices, documentation gaps, or system integration effects
  • Lead and support returned material analysis, teardown reviews, bench testing, inspection planning, fault isolation, and failure replication activities
  • Document failure modes, root cause, contributing factors, containment actions, corrective actions, verification plans, and recurrence-prevention measures
  • Drive corrective actions through closure by ensuring actions have owners, due dates, verification methods, and measurable field-improvement outcomes
  • Identify reliability and maintainability trends from field failures, repeat defects, maintenance data, test results, and product health indicators
  • Recommend new tests, inspections, diagnostics, design changes, process changes, maintenance updates, or supplier quality actions to prevent recurrence
  • Provide technical input to product health reviews, reliability readouts, sustainment reviews, fleet readiness assessments, and leadership updates
  • Support development and improvement of R&M processes, including field failure review, FRACAS, RCCA, reliability growth tracking, maintainability feedback loops, and corrective action management
  • Work with Product Engineering to ensure field-failure findings are translated into design improvements, retrofit plans, software updates, service actions, or configuration changes where appropriate
  • Work with Quality and Manufacturing to determine whether failures are linked to process escapes, inspection gaps, workmanship issues, supplier defects, or production variation
  • Work with Fleet Support and Operations to understand operational impact, maintenance burden, customer effects, and urgency of fielded system issues
  • Provide clear technical recommendations on containment, inspection, repair, replacement, retrofit, service guidance, or fleet-level mitigation
  • Communicate investigation findings, risks, corrective actions, and verification status clearly to technical teams, sustainment leadership, and cross-functional stakeholders
  • Support X-BAT lessons learned where V-BAT reliability, maintainability, and field-failure experience can inform future design, sustainment, diagnostics, repairability, and lifecycle planning

Qualifications

  • Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Electrical Engineering, Systems Engineering, Reliability Engineering, or a related technical discipline, or equivalent practical experience
  • 4+ years of experience in reliability engineering, maintainability engineering, failure analysis, systems engineering, quality engineering, aviation sustainment, product support, manufacturing engineering, or complex hardware sustainment
  • Demonstrated experience conducting technical investigations for field failures, repeat defects, hardware issues, system-level issues, or complex product performance problems
  • Experience driving Root Cause and Corrective Action investigations from initial problem statement through containment, root cause, corrective action, verification, and closure
  • Strong ability to analyze hardware, software behavior, logs, test data, returned material, field reports, configuration history, maintenance records, and operational context
  • Familiarity with structured problem-solving and failure-analysis methods such as 5 Whys, fault tree analysis, fishbone diagrams, 8D, FMEA/FMECA, FRACAS, fault isolation, or similar methods
  • Ability to distinguish between design, manufacturing, supplier quality, configuration, software, operator, environmental, maintenance, and documentation-related contributors
  • Experience working across Product Engineering, Fleet Support, Quality, Manufacturing, Reliability Data Engineering, Supply Chain, and Operations to resolve technical issues
  • Strong technical judgment and problem-solving skills, including the ability to investigate ambiguous field reports, identify likely failure modes, and define practical next steps
  • Ability to convert technical findings into clear corrective actions, verification plans, risk assessments, and product or process improvement recommendations
  • Experience supporting customer-impacting technical issues in aviation, unmanned systems, robotics, defense, manufacturing, aerospace, or complex electromechanical systems
  • Strong written and verbal communication skills, including the ability to document technical findings, investigation rationale, corrective actions, and leadership-level summaries
  • Ability to operate independently while partnering with senior technical leaders to drive cross-functional accountability without direct authority
  • Ability to balance engineering rigor, investigation depth, field urgency, customer impact, and fleet-readiness needs
  • Ability to possess a Secret DoD security clearance as required by customers

Skills

Required:Root Cause and Corrective Action (RCCA)Failure analysisData analysis of logs, test data, and maintenance records
Nice to have:FRACAS
Last updated Oct 23, 2026. Interested? Apply on the company site.

About Shield AI

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Our mission is to protect service members and civilians with intelligent systems.

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