KDC Group Services Ltd
Reliability Engineer
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Reliability Engineer - Life Extension Study
Job Purpose / Objective
To conduct a comprehensive paper-based reliability and design review to evaluate the potential for life extension of two critical components fitted to a military jet platform:
- EEPROM device(s)
- Air Data Module (incorporating Pitot and Angle of Attack (AoA) sensors)
The primary goal is to determine whether the original design life can be safely and economically extended, identify opportunities for extension, highlight technical blockers, and define the further work (including any physical inspection, test, or data-gathering activities) required to support a formal life extension case.
Key Responsibilities
- Review of Baseline Documentation
- Thoroughly review all available original design specifications, qualification test reports, reliability predictions (MTBF, failure rate data), FMECA, and safety analyses for both the EEPROM and the Air Data Module.
- Extract and document the original design assumptions, environmental profiles, duty cycles, and declared service lives / overhaul intervals.
- Design Analysis for Life Extension Potential
- Analyse the design architecture, materials, components, and failure modes of the EEPROM device, focusing on data retention, endurance cycling, temperature effects, and electrical stress.
- Analyse the Air Data Module design, including crystal (quartz oscillators) Pitot pressure sensors, AoA vanes/probes, associated electronics, and mechanical interfaces), paying particular attention to fatigue, corrosion, erosion, sensor drift, contamination, and environmental degradation mechanisms.
- Identify design margins, conservative assumptions, and areas where the original reliability estimates may support extended life (e.g., low utilisation, benign operating conditions, over-specification of components).
- Identification of Life Extension Blockers & Risks
- Highlight any technical, certification, or obsolescence-related blockers to life extension.
- Assess the impact of in-service modifications, software updates, or platform-specific usage that may differ from the original design assumptions.
- Evaluate known or emerging failure modes, reliability data from the fleet, and any relevant service difficulty reports.
- Definition of Future Actions
- Produce a clear roadmap of additional activities required to mature the life extension case, including (but not limited to):
- Targeted physical inspections, non-destructive testing (NDT), or teardown examinations.
- Accelerated life testing or environmental stress screening recommendations.
- Component sampling strategy and acceptance criteria.
- Updated reliability modelling / Weibull analysis.
- Any necessary design modifications, part replacements, or maintenance schedule changes.
- Prioritise actions by risk, cost, and feasibility.
- Produce a clear roadmap of additional activities required to mature the life extension case, including (but not limited to):
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Note: This is a paper study only. The role does not include hands-on disassembly, physical inspection, or laboratory testing at this stage. The engineer will, however, specify the scope and requirements for any such future physical work.
Essential Qualifications & Experience
- HNC/ HND/Degree (or equivalent) in Engineering (Reliability, Aerospace, Mechanical, Electronics, or related discipline).
- Significant experience in reliability engineering within aerospace or defence, preferably on military platforms.
- Strong background in electronic component reliability (EEPROMs, sensors, avionics) and/or mechanical/sensor systems (pitot, AoA).
- Familiarity with relevant standards: MIL-STD, DEF STAN, RTCA DO-160, ARP4761, ARP4754, etc.
- Experience producing technical justifications for continued airworthiness or life extension.
- Proven ability to conduct detailed design and reliability reviews using only documentation.
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Desirable Experience
- Previous involvement in military aircraft component life extension or ageing aircraft programmes.
- Knowledge of EEPROM data retention physics and failure mechanisms.
- Experience with Air Data Systems / Pitot-Static / AoA systems.
- Working knowledge of formal airworthiness processes (e.g., Military Type Certificate, Service Modification, etc.).
Key Skills & Attributes
- Excellent analytical and technical report writing skills.
- Ability to work independently with complex technical data.
- Strong attention to detail and structured problem-solving approach.
- Clear communication of technical risk to both engineering and non-engineering stakeholders.
- Proficient in reliability tools and techniques (FMEA/FMECA, reliability block diagrams, Weibull analysis, etc.).
Deliverables
- Interim findings summary (mid-study).
- Final Life Extension Assessment Report, including:
- Executive summary
- Detailed analysis for EEPROM and Air Data Module
- Life extension opportunities identified
- Blockers & risks
- Recommended follow-on actions with estimated effort and success criteria
- Supporting data registers / traceability matrix.
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