Sr. Systems Reliability Engineer

Zone 5 Technologies is seeking a Senior Systems Reliability Engineer to lead reliability and maintainability activities across the product lifecycle for unmanned aircraft systems. The role owns R&M architecture, analysis, documentation, reliability testing, customer reviews, and risk and corrective-action processes.

Responsibilities:

• 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
• 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
• 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
• 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

Requirements:

• 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
• 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