Design for Reliability (DFR) Engineer (Contract)

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Job Description: Design for Reliability (DFR) Engineer

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Experience Required: Minimum 5 years in Design for Reliability

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Domain Preference: Medical Devices (preferred but not mandatory)

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Job Type: Contract

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Location: Bangalore

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Role Summary

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We are seeking an experienced Design for Reliability (DfR) Engineer with strong analytical, testing, and Physics of Failure (PoF) modelling skills to support the design and development of high reliability products. The ideal candidate will be capable of driving reliability activities end to end including test planning, accelerated life testing, statistical modelling, root cause analysis, and robust documentation within a regulated environment. Experience in the medical device industry is highly preferred.

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Key Responsibilities

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1. Field Data Analytics & Statistical Modelling

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Perform field return data analysis using Weibull, Exponential, Lognormal, Chi square and other life data distributions .

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Develop failure rate predictions and reliability growth assessments.

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Identify dominant failure modes and drive corrective actions.

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2. Physics of Failure (PoF) Modelling

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Apply PoF-based reliability models such as:

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o Temperature cycling fatigue (Coffin Manson, Norris Landzberg)

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o Solder joint fatigue / electronics wear out

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o Arrhenius and Eyring acceleration models

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o Cumulative damage & stress life (S N) methodologies

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o Humidity related degradation models (Peck s model)

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Correlate predicted stresses with real-world mission profiles and test outcomes.

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Provide design guidance to mitigate wear out mechanisms and improve long-term robustness.

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3. Mission Profile Development & Reliability Test Protocols

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Build detailed mission profiles based on user environment, usage cycles, load conditions, and life expectations.

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Create HALT, ALT, Life Test protocols tailored to predicted failure mechanisms.

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Define stresses, acceleration factors, acceptance criteria, and sample sizes.

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4 . Test Execution & Data Analysis

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Conduct HALT/ALT/Life tests in-house or at external labs.

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Set up test fixtures, monitor tests, ensure correct stress application, and maintain data integrity.

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Analyze test results and correlate with PoF and statistical models.

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5. Documentation & Reporting

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Generate high-quality test protocols, risk assessments, test plans, and final reports.

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Ensure all documentation meets medical device regulatory expectations

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Maintain version-controlled reliability documentation within PLM systems.

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6. Fixtures, Jigs & Test Setup Development

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Design and develop mechanical, electrical, and electro-mechanical jigs/fixtures to support reliability stress testing.

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Work with cross-functional teams to fabricate and validate test setups.

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7. Reliability Analyses (Electronics & System Level)

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Perform Derating Analysis , Part Count , and Part Stress Analysis on electronic assemblies.

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Provide recommendations for component selection, thermal management, and reliability improvement.

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Support DFMEA / PFMEA activities as needed.

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8 . Software Tools & Data Management

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Work with Windchill for documentation management, configuration control, and change management.

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or

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Use ReliaSoft (Weibull++, ALTA, BlockSim, etc.) for reliability modelling and analysis.

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Maintain accurate and traceable recording of all test data.

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9. Project Planning & Deliverables

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Develop reliability deliverable plans aligned with product development phases.

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Track milestones, provide progress updates, and support cross-functional program management.

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10. Data Recording & Traceability

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Record test data, test setup parameters, environmental conditions, and test results with meticulous accuracy.

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Maintain compliance with quality systems and regulatory requirements.

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Qualifications

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Must Have

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Bachelor s or Master s degree in , Electronics, Biomedical, Reliability Engineering , or related fields.

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5+ years of hands on experience in Design for Reliability.

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Strong statistical modelling and PoF modelling expertise.

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Experience designing and running HALT/ALT/Life Tests.

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Demonstrated ability to conduct derating, part stress, and part count analyses.

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Proficiency in ReliaSoft or Windchill .

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Preferred

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Power BI Experience

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VBA Macro

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Soft Skills

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Excellent problem solving skills and attention to detail.

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Strong documentation, communication, and cross-functional collaboration capabilities.

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Ability to manage multiple tasks and deliver on time.

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Proactive mindset focused on prevention and design robustness.

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