GERRELL & HARD LIMITED
Reliability Engineer
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Reliability Engineer Electronics
This role can be based in Milton Keynes or Great Yarmouth, or home based with willingness travel to one of these sites
Travel: Occasional UK and international travel
Security Clearance: SC clearance, or eligibility to obtain
The Opportunity
We are looking for an experienced Reliability Engineer to take ownership of reliability activities for advanced hybrid electronic systems operating in extreme, high-temperature environments.
The role will focus on proving and improving the reliability of high-temperature electronics, identifying potential failure mechanisms and working with engineering teams to reduce risk and improve product performance throughout the product lifecycle.
You will work closely with electrical, mechanical, materials, manufacturing and quality engineers, supporting the development of products used in demanding industries including aerospace, defence and oil & gas.
This is a technically hands-on role combining reliability engineering, failure analysis, materials, electronics and thermal management.
Key Responsibilities
Reliability Analysis & Testing
- Develop and execute reliability test plans for high-temperature electronic hybrid designs.
- Conduct stress analysis, life testing and failure mode analysis.
- Plan and support Accelerated Life Testing (ALT) and Highly Accelerated Life Testing (HALT).
- Investigate failure mechanisms including thermal fatigue, electromigration and oxidation.
- Analyse test results and identify opportunities to improve product reliability.
- Work with laboratory and test teams using thermal chambers and specialist reliability test equipment.
Design for Reliability
- Work with engineering teams to build reliability into products from specification and design through to production.
- Lead or contribute to DFMEA, FMEA and Fault Tree Analysis (FTA) activities.
- Provide reliability input at key product development and design reviews.
- Recommend design changes to improve reliability and reduce product risk.
- Act as a technical authority on reliability matters within the business.
Materials & Components
- Support the qualification of materials and components for extreme environments.
- Assess and recommend suitable ceramics, adhesives, alloys and electronic components.
- Support material trials, testing and requalification activities.
- Contribute to component and material obsolescence management.
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Data Analysis & Reporting
- Analyse reliability and test data to identify trends and failure patterns.
- Apply reliability prediction and statistical techniques, including Arrhenius and Weibull analysis.
- Produce technical reports and presentations for internal and external stakeholders.
- Present reliability findings and recommendations to senior stakeholders and customers.
- Provide clear, evidence-based recommendations for improving product reliability.
Standards & Compliance
- Ensure reliability activities comply with relevant industry and customer standards, including applicable MIL-STD requirements.
- Maintain knowledge of reliability testing standards, methods and emerging technologies.
- Research new reliability methodologies and identify opportunities to improve testing and product assurance.
Collaboration & Continuous Improvement
- Work closely with design, manufacturing and quality teams to resolve reliability issues.
- Collaborate with suppliers, external laboratories and technical partners where required.
- Participate in technical reviews and continuous improvement programmes.
- Lead reliability improvement activities using structured problem-solving and methodologies such as Kaizen and Lean Six Sigma.
About You
We are looking for an experienced reliability professional with a strong background in high-reliability electronics and/or harsh-environment applications.
You will ideally have:
- A degree or equivalent qualification in Electrical Engineering, Mechanical Engineering, Materials Science or a related discipline.
- Significant experience in reliability engineering, ideally within high-reliability electronics.
- Strong hands-on experience with reliability testing, failure analysis and reliability data.
- Experience working with electronics manufacturing and thermal management.
- Knowledge of high-temperature semiconductor technologies such as SiC and GaN.
- Experience with hybrid electronic technologies such as LTCC, HTCC and Thick Film, as well as conventional PCBs.
- Experience with harsh-environment electronics such as downhole electronics, avionics or optoelectronics.
- Understanding of failure analysis techniques including SEM, X-ray and electrical testing.
- Experience with HALT, HASS, FMEA and FTA.
- Experience using reliability prediction techniques such as Arrhenius and Coffin-Manson.
- Strong analytical and problem-solving skills.
- Excellent written and verbal communication skills.
- Experience working across multidisciplinary engineering teams.
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Desirable
The following would be advantageous:
- Certified Reliability Engineer (CRE) or equivalent qualification.
- Lean Six Sigma certification.
- Experience using engineering/reliability software such as Windchill.
- Experience conducting internal audits of engineering data and processes.
- Experience working with defence, aerospace, oil & gas or other safety-critical/high-reliability products.
- Experience working with customers and suppliers on reliability programmes.
What You'll Be Doing Day-to-Day
This role offers a combination of technical analysis, hands-on testing and engineering collaboration.
You could be analysing failure data in the morning, working with an engineering team on a design change, reviewing a DFMEA, investigating a failed component or setting up a high-temperature reliability test in the laboratory.
The focus throughout is on one key objective:
Understanding how and why products fail in extreme environments, then using that knowledge to make them more reliable.
Location & Travel
The role can be based from either Milton Keynes or Great Yarmouth, with hybrid working available.
The position is primarily office and laboratory based, with occasional travel to:
- Manufacturing facilities
- Test laboratories
- Supplier sites
- Customer locations
- Overseas company sites across the US, Europe and Asia
SC clearance is required or candidates must be eligible to obtain it.
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