Senior Staff Reliability Engineer

Summary

Join Agility Robotics, a pioneer in humanoid robotics, as a Senior Staff Reliability Engineer. Lead hardware reliability efforts for our groundbreaking robot, Digit, ensuring its performance, safety, and durability. Develop and implement a comprehensive reliability engineering strategy, collaborating with cross-functional teams. Design and execute reliability testing, analyze results, and drive data-informed decisions. Conduct failure analysis, implement corrective actions, and validate hardware components. Improve product reliability, reduce failure rates, and mentor junior engineers. This role requires extensive experience in reliability engineering for complex hardware systems, particularly in robotics or related high-reliability industries.

Requirements

• Minimum of 15 years of experience in reliability engineering for complex hardware systems
• Extensive experience with reliability engineering principles, including component derating, FMEA/DFMEA, and Coffin-Manson analysis for fatigue prediction
• Proficiency in reliability testing methods such as HALT, HASS, vibration, and thermal cycling
• Strong understanding of mechanical systems, electronic components (PCBAs, motor controllers), sensors, and materials science
• Exceptional problem-solving and analytical skills, with a focus on data-driven decision-making
• Excellent communication and collaboration abilities, capable of working with cross-disciplinary teams and suppliers
• Proven ability to lead RCA efforts, implement corrective actions, and drive reliability improvements
• Bachelor’s degree in Mechanical Engineering, Electrical Engineering, or a related field (Master’s or PhD preferred)

Responsibilities

• Develop and implement a comprehensive reliability engineering strategy for hardware systems, with a focus on actuators, motor controllers, PCBAs, sensors, limbs, and end effectors
• Establish and maintain reliability metrics, goals, and test protocols for each product lifecycle stage, from design to production
• Collaborate closely with cross-functional teams (mechanical, electrical, firmware, and manufacturing) to integrate reliability principles into design and development processes
• Ability to design reliability testing approaches that extract meaningful insights from small sample sizes , as large, statistically significant sample sizes (30+ units) are typically not available at our stage.  Must leverage statistical methods, engineering judgment, and accelerated testing techniques to drive data-informed decisions
• Apply component derating principles to ensure hardware components operate well within their rated limits, improving system reliability and longevity
• Analyze thermal, electrical, and mechanical stresses to identify potential failure points and recommend design adjustments
• Perform Coffin-Manson fatigue analysis to predict the lifecycle of materials and components under cyclic thermal and mechanical loading
• Lead root cause analysis (RCA) for hardware failures, implementing corrective actions and preventative measures
• Develop and oversee reliability testing plans, including Highly Accelerated Life Testing (HALT), Highly Accelerated Stress Screening (HASS), vibration testing, and environmental stress testing
• Analyze field data, prototype testing results, and production feedback to identify trends and drive improvements
• Validate critical hardware components, including actuators, motor controllers, sensors, and PCBAs, through rigorous testing and analysis
• Drive Design for Reliability (DfR) methodologies, including FMEA, DFMEA, stress analysis, and reliability growth modeling
• Partner with suppliers to verify the reliability and quality of sourced components, ensuring alignment with design and reliability standards
• Identify and implement design and process improvements to enhance product reliability, reduce failure rates, and improve durability
• Contribute to the development of reliability standards, documentation, and best practices to guide future hardware development
• Provide reliability reports, insights, and recommendations to stakeholders, including engineering leadership and executive teams
• Mentor and coach junior engineers, fostering a strong culture of reliability across the organization

Preferred Qualifications

Strong preference for candidates with experience in robotics, autonomous vehicles, aerospace, or other high-reliability industries

Benefits

• 401(k) Plan: Includes a 6% company match
• Equity: Company stock options
• Insurance Coverage: 100% company-paid medical, dental, vision, and short/long-term disability insurance for employees
• Benefit Start Date: Eligible for benefits on your first day of employment
• Well-Being Support: Employee Assistance Program (EAP)
• Time Off: Exempt Employees: Flexible, unlimited PTO and 10 company holidays, including a winter shutdown
• Time Off: Non-Exempt Employees: 10 vacation days, paid sick leave, and 10 company holidays, including a winter shutdown, annually
• On-Site Perks: Catered lunches twice a week and a variety of healthy snacks and refreshments at our Salem and Pittsburgh locations
• Parental Leave: Generous paid parental leave programs
• Work Environment: A culture that supports flexible work arrangements
• Growth Opportunities: Professional development and tuition reimbursement programs
• Relocation Assistance: Provided for eligible roles