Sr. Systems Reliability Engineer

At Zone 5 Technologies, we're redefining what's possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting-edge autonomous solutions that push the boundaries of UAS technology - solving complex challenges that matter.

We're building the future of UAS capabilities, and we're looking for exceptional talent to join us. If you're driven by hard problems, energized by rapid innovation, and ready to make an impact on next-generation flight systems, you belong here.

We are seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle. This role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. You will engage directly with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews.

Key Responsibilities:

Reliability & Maintainability Architecture

• Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C (Reliability, Availability, Maintainability-Cost) Rationale Report

• Lead Failure Modes, Effects, and Criticality Analysis (FMEA/FMECA), Fault Tree Analysis (FTA), and Reliability Block Diagram (RBD) development across system architecture

• Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support R&M requirements analysis and trade studies

• Draft Reliability Predictions (per MIL-HDBK-217 and related methods) and Maintainability Analyses; maintain traceability between R&M requirements, predictions, and demonstrated performance

• Lead Reliability-Centered Maintenance (RCM) and Level of Repair Analysis (LORA); support Testability and Built-In Test (BIT) analysis

Data, Documentation & Test Planning

• Establish and own the Failure Reporting, Analysis, and Corrective Action System (FRACAS); maintain closed-loop failure data collection and trending from design through test, production, and sustainment

• Develop Failure Definitions and Scoring Criteria (FDSC) and reliability test plans tied to program milestones

• Lead reliability growth planning and execution of reliability growth and demonstration testing, including Environmental Stress Screening (ESS) and HALT/HASS where applicable

• Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments

• Develop technical documentation including R&M standards, specifications, procedures, and user guides

• Review ground test, flight test, and live-fire test data to confirm R&M requirements compliance

Customer Engagement & Reviews

• Serve as primary point of contact with customers on R&M matters

• Present R&M analyses, RAM-C Rationale Report updates, and risk posture at Milestone Reviews (A/B/C) and design reviews (PDR, CDR, TRR, PRR)

• Lead Reliability Scoring Conferences and Corrective Action Boards (CAB) with customer participation

• Coordinate responses to customer R&M data item deliverables and support In-Service Reviews

Risk Management & Process Improvement

• Lead Root Cause and Corrective Action (RCCA) investigations for failures identified through FRACAS

• Host corrective action reviews and ensure lessons learned are implemented across the program

• Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence and shelf-life and aging surveillance considerations

• Apply digital engineering and AI-enabled tools (predictive maintenance, digital twins, automated FRACAS analytics) to R&M processes

• Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards

Basic Qualifications:

• 7+ years as a Reliability Engineer, R&M Engineer, or equivalent reliability-critical engineering role

• Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics

• Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards

• Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure

• Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening

• Experience engaging with customers on R&M reviews and milestone/design reviews (PDR, CDR, Milestone B/C)

• Strong system architecture knowledge and R&M requirements decomposition and allocation

• Extensive FMEA/FMECA, FTA, and RBD experience

• Failure investigation with proven corrective action implementation

• Technical writing for R&M program plans, rationale reports, procedures, and documentation

• Design review experience (PDR, CDR, MRR) with strong presentation skills

• Data collection, analysis, and trending for R&M metrics

• U.S. Citizenship

Preferred Qualifications:

• Master's degree in engineering or related field

• 10+ years progressive R&M experience

• ASQ Certified Reliability Engineer (CRE) or equivalent certification