Failure Analysis and Sustaining Engineer

Mastech Digital provides digital and mainstream technology staff as well as Digital Transformation Services for all American Corporations. We are currently seeking a Failure Analysis and Sustaining Engineer for our client in the Software domain. We value our professionals, providing comprehensive benefits and the opportunity for growth. This is a Contract position, and the client is looking for someone to start immediately.

Duration: 6+ Months Contract

Location: San Mateo, CA (4 days a week at lab in San Mateo)

Salary: $60.00-$65.00/Hourly or $115,000-$120,000/Annually

Role: Failure Analysis and Sustaining Engineer

Primary Skills: SQL

Role Description: The Failure Analysis and Sustaining Engineer must have 3+ years of experience. Seeking a Failure Analysis and Sustaining Engineer with strong technical quality management, hands-on debugging, data analytics, and 8D-based Root Cause Corrective Action (RCCA) expertise. This role will partner closely with Hardware, Firmware, Operations, and Customer Care teams to ensure exceptional product reliability and customer experience across our connected device portfolio ? including Bluetooth trackers and LTE-M/GNSS-based wearable products.

For this role, you must be highly organized, results-driven, and comfortable working across disciplines to identify, analyze, and resolve product issues from pre-launch through sustain. Insights from your work will directly inform design improvements for next-generation devices, helping us deliver products that are dependable, durable, and delightful to use.

Key Responsibilities:

- Own and drive key quality and reliability metrics for both product families from pre-launch through field sustainment.

- Conduct in-depth electrical and system-level failure analysis on RMAs, yield fallout, and field returns, identifying root causes down to the component level.

- Collaborate with Hardware, Firmware, and Operations to ensure lessons learned feed back into the product development cycle.

- Perform PCBA debugging and electrical validation of BLE, GNSS, LTE-M, and Wi-Fi subsystems.

- Develop and refine diagnostic tools, test jigs, and FA techniques to accelerate failure identification and resolution.

- Author comprehensive FA and RCCA reports, clearly articulating findings, corrective actions, and systemic improvement opportunities.

- Leverage data analytics (SQL, Excel, Tableau) to transform test and field data into actionable technical insights.

- Utilize downtime between builds to execute hardware tweaks and validation plans, ensuring sustained quality improvement.

- Partner with contract manufacturers and component suppliers to close the loop on high-impact issues and drive long-term reliability enhancements.

Key Qualifications:

- BS/MS in Electrical Engineering, Materials Science, or equivalent field.

- 5+ years of experience in failure analysis, quality engineering, or sustaining roles supporting consumer IoT or connected wearable devices.

- Proven experience performing end-to-end 8D and RCCA investigations, including containment, verification, and systemic prevention.

- Strong electrical debug background with proficiency in RF circuits, power management, and mixed-signal design.

- Familiarity with Bluetooth LE, GNSS, LTE-M, and Wi-Fi hardware systems and their common failure modes.

- Skilled in reading schematics, interpreting layouts, and performing board-level rework and analysis.

- Proficiency with oscilloscopes, logic analyzers, spectrum analyzers, and other electronic test equipment.

- Data analytics capability ? comfortable with SQL, Excel, and visualization tools such as Tableau or Power BI.

- Excellent technical communication and documentation skills, with the ability to distill complex analysis into clear, actionable insights.

- Willingness to travel internationally up to 25% to support supplier and factory FA investigations.

Preferred Experience:

- Experience sustaining high-volume, battery-powered consumer products (e.g., wearables, trackers, or IoT devices).

- Understanding of power electronics, battery characterization, and charging circuitry.

- Prior work with contract manufacturers (Jabil, Luxshare, Inventec, etc.) and cross-functional debug across supply chains.

- Demonstrated ability to uncover systemic design or process weaknesses and implement durable corrective actions.

- Proven track record of launching new hardware products and driving continuous quality improvements through post-launch sustainment.

- Ability to thrive in a fast-paced, startup-like environment while meeting or exceeding aggressive timelines.

Education: Bachelor?s degree/MS in Electrical Engineering, Materials Science, or equivalent field

Experience: Minimum 3+ years of experience

Relocation: This position will not cover relocation expenses

Travel: No

Local Preferred: Yes

Note: Must be able to work on a W2 basis (No C2C)

Recruiter Name: Meenakshi Pal

Recruiter Phone:

Benefits:

We have various coverages and additional benefits to choose from:

- Medical, Dental (Including Ortho) & Vision Insurance (Option to Enroll).

- Paid Leaves (Wherever applicable).

- Life & Disability Coverage (Upon eligibility).

- 401K Option, Education Assistance Program and more.

Mastech Digital is an Equal Opportunity Employer - All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or protected veteran status.