Senior Failure Analysis Engineer (Starlink)

The Senior Failure Analysis Engineer at SpaceX is tasked with supporting both destructive and non-destructive analyses of production hardware. This role is crucial during the entire product lifecycle, from pre-production to qualification and flight hardware. The engineer will work directly in the Failure Analysis laboratory, interfacing with various teams to ensure manufacturing quality and investigate nonconforming products. Their findings help enhance the reliability of the world’s most advanced broadband internet system while providing valuable insights for ongoing improvement.

To qualify for the Senior Failure Analysis Engineer position at SpaceX, candidates should have a Bachelor’s degree in Material Science, Electrical Engineering, Physics, or a related STEM field, along with at least 5 years of experience in semiconductor, package, or PCBA reliability. Additionally, familiarity with failure analysis techniques and a background in working with SMT manufacturing are preferred. A Master's degree in Material Science or a similar field and extensive experience will enhance a candidate's application.

Candidates for the Senior Failure Analysis Engineer role in Starlink should possess significant experience in failure analysis on semiconductor packages and devices, with at least 4 years in this specific area. Knowledge of non-destructive and destructive analysis techniques, alongside experience with visual inspection, X-ray, and cross-sectioning, is vital. It’s also important to be skilled in supporting recovery efforts for non-conforming hardware and First Article Inspection Reports.

At SpaceX, the work environment for a Senior Failure Analysis Engineer is dynamic and fast-paced. Engineers are encouraged to think critically and work collaboratively within a cross-functional team. The role requires hands-on involvement in solving complex problems and conducting analyses, which means candidates should be comfortable working in tight spaces and handling various tools and equipment. Flexibility and a can-do attitude are essential in this high-stakes atmosphere.

SpaceX is committed to professional growth, offering opportunities for ongoing education, training, and mentorship to its Senior Failure Analysis Engineers. Engineers are encouraged to stay updated with industry best practices and advanced technologies as they contribute to groundbreaking projects like Starlink. The collaborative culture at SpaceX promotes knowledge-sharing and enables engineers to learn from each other while tackling remarkable challenges.

The compensation for a Senior Failure Analysis Engineer at SpaceX typically ranges from $130,000 to $180,000, depending on the individual’s experience, background, and overall skill set. In addition to competitive base salaries, SpaceX offers long-term incentives such as stock options, discretionary bonuses, and a comprehensive benefits package including medical, dental, vision coverage, a 401(k) plan, and more, ensuring overall employee wellbeing.

Aside from technical qualifications, a Senior Failure Analysis Engineer at SpaceX must meet certain physical and working condition requirements. This includes the ability to lift 25 lbs., work in tight spaces, use power and hand tools safely, and handle corrosive chemicals while following safety protocols. Furthermore, candidates should be prepared to work flexible hours, including all shifts, overtime, and weekends as necessary to meet project deadlines.

When asked about your experience with failure analysis techniques, structure your answer by highlighting specific techniques you've used, such as X-ray inspection or cross-sectioning. Discuss how you applied these techniques to identify and resolve issues in past projects. Mention relevant metrics or outcomes to showcase your effectiveness in this area.

When tackling semiconductor reliability issues, emphasize your methodical approach. Start by gathering data on failures, then categorize issues based on patterns you observe. Discuss your collaborative efforts with cross-functional teams to brainstorm solutions and how you've implemented corrective action to enhance reliability in production.

In your response, convey how working in fast-paced environments has enhanced your ability to prioritize tasks and manage time effectively. Share a specific example where quick decision-making was necessary, and describe the outcome, showcasing your adaptability and eagerness to tackle challenges.

Quality control is paramount in failure analysis. Discuss the protocols you implement to maintain quality at every stage, such as documenting analyses, following standardized procedures, and regularly communicating with team members. Highlight any tools or software you've used for tracking and reporting quality metrics.

Share a specific incident where a failure analysis presented significant challenges. Detail your analysis process, how you identified root causes, and the solutions you implemented. This is a great opportunity to show your critical thinking skills and your innate problem-solving abilities.

Discuss your method for addressing non-conformance by illustrating how you approach inspections and document any discrepancies. Explain how you collaborate with engineering and production teams to investigate non-conformance and implement steps to rectify any issues, ensuring to maintain compliance with regulatory standards.

In discussing your experience with destructive and non-destructive analysis methods, outline the specific techniques you are familiar with, like SEM for destructive analysis and Visual Inspection for non-destructive. Describe scenarios where you've effectively utilized both to draw valuable insights and support product advancements.

Communication is vital in failure analysis as it fosters collaboration and knowledge sharing. Describe how you ensure clear communication with team members and stakeholders throughout the analysis process, particularly when presenting findings and recommendations for improvement, making sure to emphasize transparency.

Talk about your proficiency with data analysis tools that assist in failure analysis processes. Highlight specific software or tools you've used and how they have improved your analysis efficiency. Provide examples of how data analysis has empowered you to make informed decisions during investigations.

Express your passion for innovation and technology, particularly in satellite systems like Starlink. Discuss how SpaceX's mission aligns with your values and how you see yourself contributing to their goals. Be specific about what excites you about the job and the potential impact of your work within the industry.