Test Reliability Engineer - Development Test Support

TEST RELIABILITY ENGINEER – DEVELOPMENT TEST SUPPORT

The Test Reliability organization at SpaceX is an inclusive, interdisciplinary team that is committed to the reliability of flight components and production assemblies. Your breadth of exposure as a Test Reliability Engineer will be immense as you collaborate with other core groups at SpaceX, guiding the hardware from design to production and operation. You use data to understand the factors that drive reliability and support quality objectives in design and development teams to drive improvements in reliability in manufacturing, test, and flight. You have the ability to dive deep into details to identify, understand, and solve difficult technical problems, and also utilize a system-level approach to prioritize issues for the vehicle and supporting components as a whole. You thrive in a hands-on environment and will spend time in the office, on the Development Test sites, including Falcon and Starship Component Test Stands, and/or in the materials compatibility lab to execute on the mission to make humanity interplanetary.

RESPONSIBILITIES:

• Partner with design engineering and manufacturing teams through product development and production to implement quality/reliability fundamentals for development and flight hardware, including identification of key characteristics, prototype testing for functionality and manufacturability, first article and detailed inspection planning, qualification program implementation, and consideration of past failures and lessons learned
• Develop, implement, and validate Lean test and inspection processes for new and existing products and processes; ensure criteria are objective and quality goals are consistently met
• Monitor the success of products and processes through production ramp-up using a suite of quality and analysis tools
• Conduct regular build/test/launch quality reviews to ensure that design intent is achieved and any hardware deficiencies are well-communicated; identify opportunities for risk reduction and removal of complexity in designs and processes to improve manufacturability and maintainability; collaborate with integrated product teams to drive improvements and address high-impact and repeating non-conformances
• Investigate failures in production, test and flight; identify and mitigate the immediate and underlying root causes in order to reduce risk and improve reliability of designs and processes
• Contain suspect or known non-conforming product; provide guidance to quality inspectors, technicians, shop supervisors, and engineers to assist in quarantining and rework activities
• Support the development test group in continuous improvement, the advancing of a Lean, autonomous, production system through creation of standard rework/repair guides, removal of redundant or unnecessary inspection, and improved control and optimization of critical processes

BASIC QUALIFICATIONS:

• Bachelor's degree in mechanical engineering, aerospace engineering, materials engineering, manufacturing engineering, chemical engineering, or electrical engineering
• 2+ years of experience in manufacturing, fabrication, assembly, testing, or quality experience

PREFERRED SKILLS AND EXPERIENCE:

• Engineering experience at SpaceX
• Strong interpersonal and collaborative skills; enthusiasm for the team’s spirit of innovation and mission of improving reliability in cutting-edge technology
• Master’s degree in mechanical engineering, aerospace engineering, materials engineering, or electrical engineering
• Demonstrated application of process controls in a high-volume manufacturing, test, and quality environment
• Dedicated to adopting a Lean approach to quality without compromising safety or reliability
• Knowledge of quality tools such as Lean principles, measurement systems analysis, design of experiments, statistical process control, root cause analysis and corrective action, advanced product quality planning (APQP), metrology, process failure mode and effects analysis (PFMEA), control plans, and various problem-solving approaches
• Experience developing or supporting any of the following products/processes:




• Complex mechanical/structural assemblies
• Advanced composites systems
• Fluid component/valve assembly
• Prepreg lamination/curing composites
• CNC machining, forming, bending
• Bonding, drilling, fastening, and other assembly manufacturing processes
• Avionics integration and testing
• Fluid system pressure testing
• Welding (electron beam (EB), TIG)

ADDITIONAL REQUIREMENTS

• Flight hardware is typically built in tight quarters and physical dexterity is required
• Physical effort including sitting or standing for extended periods of time, lifting and carrying weight such as materials or equipment up to 25 lbs. unassisted
• Work performed in an environment with exposure to fumes, odors and noise
• Occasionally exposed to work in extreme outdoor environments (heat, cold, rain)
• Must be available to work extended hours, weekends, and shifts, which varies depending on site operational needs; flexibility required