Senior Reliability Engineer - C4ISR Systems

Job Description BAE Systems is a leading global defense, security, and aerospace company. We deliver a full range of products and services for air, land and naval forces, as well as advanced electronics, information technology solutions, and cyber security. We are experiencing significant growth, driven by innovation and a commitment to supporting our customers. Join us and be a part of something bigger!

We are seeking a motivated and detail-oriented Reliability Engineer to join our dynamic C4ISR (Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance) Systems team. This position offers an excellent opportunity for a recent graduate or early-career professional to gain hands-on experience in a critical engineering discipline, supporting cutting-edge technologies and contributing to national security. You will play a vital role in ensuring the reliability and performance of our systems, working alongside experienced engineers and contributing to continuous improvement. This role is designed for growth, with opportunities to expand your skill set and take on increasing

• •Collect, analyze, and interpret reliability data from various sources (field failures, testing, simulations) to identify trends, potential areas for improvement, and quantify product reliability.
• •Utilize statistical tools and techniques (Weibull analysis, MTBF/MTTR calculations, FMECA, Root Cause Analysis, hypothesis testing) to assess system reliability and predict future performance.
• •Develop and maintain reliability prediction models to assess design margins and optimize product life.
• •Perform Reliability Growth Analysis to track improvement over time.
• •Contribute to the development of reliability test plans and strategies.

Failure Analysis & FRACAS (Failure Reporting, Analysis, and Corrective Action System)

• •Analyze failed hardware and software components from production and field returns to determine root cause of failures and assist in developing corrective actions. This includes understanding failure mechanisms and applying engineering principles to diagnose issues.
• •Collaborate with internal teams (Quality, Hardware Design, Manufacturing, Software Engineering) to gather information, facilitate investigations, and implement solutions.
• •Interface with Suppliers/Vendors to review their failure analysis findings, ensure alignment, and drive resolution of supplier-related issues.
• •Perform detailed failure analysis using a variety of techniques (visual inspection, microscopy, component-level testing, data analysis, and potentially more advanced techniques like X-ray or SEM depending on your product).
• •Author clear, concise, and technically accurate customer-facing failure reports and narratives, including recommended corrective actions and clear communication of technical issues.
• •Maintain and update the FRACAS database with accurate failure data, analysis results, and corrective action tracking.
• •Review and interpret data from manufacturing process monitoring, environmental stress screening (ESS), and system testing to identify potential reliability concerns.
• •Collaborate with test teams to investigate failure modes, refine test procedures, and improve test coverage.

• •Perform Maintainability analysis, estimate Mean Time To Repair (MTTR), and identify opportunities to improve product serviceability.
• •Perform system-level testability analysis and demonstrate the effectiveness of diagnostic features.
• •Support the development and implementation of diagnostic procedures to facilitate efficient troubleshooting.

• •Create and maintain detailed documentation of failure analysis results, test procedures, reliability data, and analysis reports.
• •Prepare and deliver presentations summarizing reliability findings for internal stakeholders (engineering teams, management) and potentially external stakeholders (customers, vendors).