Staff Electrical Failure Analysis Engineer (NJ)

Job description

About the Role The Electrical Failure Analysis Engineer supports manufacturing and quality operations by leading electrical root cause analysis (RCA), failure characterization, and corrective action activities across server, rack, cable, connector, and electromechanical hardware platforms. This role focuses on identifying failure mechanisms, developing fault isolation methodologies, and driving systemic corrective actions to improve product quality, reliability, and manufacturing yield. The Electrical Failure Analysis Engineer works closely with Metrology Engineers, Supplier Quality Engineers, Manufacturing Engineering, Design Engineering, and Reliability teams to investigate electrical failures occurring during incoming inspection, manufacturing, system integration, qualification testing, and field operation. This position applies electrical troubleshooting, statistical analysis, and structured problem-solving methodologies to identify root causes and prevent recurrence in high-volume manufacturing environments. What You Will Do Lead electrical failure investigations involving connectors, cable assemblies, wire harnesses, power distribution systems, CB assemblies, and electromechanical components. Perform root cause analysis of electrical defects including opens, shorts, intermittent connections, excessive resistance, insulation breakdown, and ESD-related failures. Develop and execute fault isolation plans using electrical test equipment and laboratory analysis techniques. Correlate electrical failure signatures with dimensional, mechanical, and metrology data to identify failure mechanisms and process drivers. Drive containment, corrective actions, and preventive actions through structured methodologies including &D, DMAIC, and CAPA processes. Partner with Manufacturing, Supplier Quality, and Engineering teams to resolve electrical nonconformances and improve product reliability. Develop electrical test methods, inspection procedures, and validation protocols to support manufacturing and quality operations. Support qualification, reliability, and environmental testing activities including thermal cycling. vibration, HALT, and HASS investigations. Analyze failure trends, field return data, and manufacturing defects to identify recurring issues and improvement opportunities. Review engineering drawings, schematics, wiring diagrams, and specifications to support failure analysis activities. Generate detailed technical reports documenting failure mechanisms, root causes, test results, and corrective actions. Support supplier audits, supplier corrective actions, and component qualification activities related to electrical and cable assembly suppliers. Establish and What You Bring Bachelor's degree in Electrical Engineering, Electronics Engineering. Physics, or related technical field. 6+ years of experience in Electrical Failure Analysis, Hardware Quality Engineering, Reliability Engineering, Manufacturing Quality, or related disciplines. Strong troubleshooting experience with electrical and electronic systems. Hands-on experience performing root cause investigations in manufacturing, quality, or reliability environments. Experience using structured problem-solving methodologies including 8D, DMAIC, Fishbone Analysis, 5-Why, and FMEA. Experience with electrical test equipment including: Digital Multimeters (DMM) Oscilloscopes LCR Meters Power Supplies Continuity Testers a Insulation Resistance Test Equipment Ability to read and interpret electrical schematics, wiring diagrams, assembly drawings, and specifications. Experience supporting supplier quality investigations and corrective action processes. Strong analytical skills with the ability to interpret data and identify failure trends. Excellent technical communication and report-writing skills. Nice to Have Experience with Al servers, data center hardware, networking equipment, storage systems, or rack-level integration. Experience with cable assemblies, wire harnesses, high-current power systems, and connector reliability. Working knowledge of TDR (Time Domain Reflectometry) for cable and fault localization analysis. Experience using Vector Network Analyzers (VNA) and performing basic signal integrity evaluations. Familiarity with PCle, Ethernet, InfiniBand, SAS, NVLink, or other high-speed interconnect technologies. IPC/WHMA-A-620 certification or familiarity with wire harness and cable assembly standards. Six Sigma Green Belt or Black Belt certification. Experience working with EMS, ODM, or complex global supply chains. Familiarity with reliability testing methodologies and environmental stress testing. ZT Systems assesses market data to ensure a competitive compensation package is created for all our employees. The typical base salary for this position is expected to be between $93,000 and $136,400 annually. If hired, the final base salary will be determined on an individual basis taking into consideration experience, skills, knowledge, education and/or certifications. Base salary is just one component of ZT Systems total rewards philosophy. We take pride in offering a wide range of benefits and perks that appeal to the variety of needs across our diverse employee base. Other rewards may include bonus, paid time off, generous 401k match, tuition reimbursement, wellbeing resources, and more. We are dedicated to building a diverse, inclusive, and authentic workplace, so if you’re excited about this opportunity but your experience doesn’t align perfectly with every qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles. #LI-DH1 About ZT Systems At ZT Systems, a Sanmina Company, you’ll get to do work you are proud of alongside smart, passionate people. Every day, there are opportunities to collaborate with the best in the industry to design, build, and deliver impactful solutions to world-class customers. Along the way, you will gain hands-on experience in a fast-paced environment that’s challenging, rewarding, and career-defining. A culture built around our values we work hard and think fast. We view challenges as opportunities—to do better, push harder, and be faster than we were the day before. When we fail, we learn from it and move on together. And when we succeed, we use the momentum to go even further. We create value with everything we do, building the foundation of today—and transforming the future of tomorrow. Join ZT Systems and help us build technology infrastructure that connects the world. What We Offer At ZT Systems, a Sanmina Company, we believe that investing in our people is key to our continued growth and innovation. When you join our team, you’ll gain access to a comprehensive and inclusive benefits package designed to support your well-being, financial security, and professional development—both now and in the future. Compensation & Financial Security -Competitive base salary -Performance-based annual bonus eligibility -401(k) retirement savings plan -Tuition reimbursement for eligible education programs Health & Wellness -Comprehensive medical, dental, and vision coverage with access to leading providers -Mental health resources and employee wellness support programs- -Company-paid life and disability insurance Time Away & Work-Life Balance -Paid time off (PTO) and company-paid holidays -Parental leave and family care support programs Growth & Purpose -Structured training programs and on-the-job learning opportunities -Matching gifts and volunteer programs to support causes you care about These benefits are available to eligible employees and are designed to grow with you as your career evolves. Full benefits and eligibility varies by work location. Learn more about our benefits here. ZT Group Int’l. is an Equal Opportunity Employer and prohibits discrimination and harassment of any kind. ZT Systems provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. Please be aware that certain positions may require the applicant to either 1) be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or 2) be eligible to obtain an export control license or license exception from the Bureau of Industry and Science & U.S. Department of Commerce. All offers of employment will be conditional subject to the foregoing.