Senior Manager - Reliability & Testing (COE Leader)

Job Description

KEY RESPONSIBILITIES Global responsibility for developing and driving standardized Design for Reliability Engineering (DfRE) and Robustness Validation (RV) Methodologies for all DDN Product Lines. Create a DDN DfRE/RV Training Program and roll out globally to all functions involved in product development: Product Design Engineering (PDE); Manufacturing Process Development Engineering (MPDE); PMO/Project Management; Advanced Quality + Customer Quality + OPS/MFG Quality; Field Application Engineering (FAE). This program will drive what good looks like” and will be expected mandatory requirement implemented on all DDN Programs. Drive a DFSS culture, one of innovation, constant learning, and continuous improvement that aspires to deliver "First Time Right"; provide product development and DFSS training, coaching, and mentoring to product design teams to create a world class product development organization. Drive excellence in Design for Reliability ensuring comprehensive utilization of modeling and simulation, structured DOE approaches, robust product validation including HALT/HAST and Test to Failure (TTF) methodologies. Oversee integrating reliability considerations during technology & product evaluation, NPI product development from receipt of Customer Spec (Mission Profile) through Product Release into mass production; will have T&V Plan + Reliability Test Plan Finalization Authority for each DDN Program. Lead development of Test Equipment & Testing Specifications: Architecture, development and maintenance of standardized and optimized (custom if necessary) global platform test systems, data acquisition, software and test fixtures for specific needs of each DDN Product Line. Develop test specifications for TE in-house testing as well as any external testing (contracted labs, suppliers, ODMs etc). Lead Global Testing Services: Work directly with PDE Teams and PMO to coordinate all Reliability Testing and T&V Plans including environmental, mechanical, electrical, electronic, EMI/EMC and software testing of the following: Components, Sub-Assemblies (including PCBAs), Finished Products, Application Testing, and Customer Specific Testing. Coordinate all TE in-house testing as well as any external testing (contracted labs, suppliers, ODMs, etc). Drive high performance organization by providing your team routine coaching and feedback, holding your team accountable to meet performance objectives, and providing meaningful development to increase individual/team capability. Manage employee well-being by prioritizing work, effectively managing resource loading, and providing flexibility to enable employees to successfully balance their work and personal lives. Drive organization effectiveness by structuring your organization in a way that best enables the BU strategy, maximizes resource efficiency and productivity, and provides role clarity and clear lines of accountability. Manage the talent in your organization to support the business now and to proactively prepare for the future by identifying organization skillset/role gaps, implementing plans to fill any skillset/role gaps, and assessing current talent fit to ensure the right talent is matched to the right roles to best meet the needs of the business. DfRE’s IN GLOBAL R&T COE WILL HAVE FOLLOWING RESPONSIBILITIES: Integrate reliability considerations during technology & product evaluation, NPI product development from receipt of Customer Spec (Mission Profile) through Product Release into mass production. Contribute towards requirement engineering. Understand the load requirements clearly to derive inner load and stresses. Drive reliability planning tailored to environmental and use conditions, integrating contingency planning and business impact. Analysis of test data. knowledge on data acquisition methods and system. Apply accelerated test models and test-to-failure strategies to determine reliability limits and identify failure modes. Perform the initial FIT estimation based on data from standards such as Siemens Norm SN-29500. Calculate final FIT value based on test data. Analyze customer requirements, application requirements and mission profile to determine the optimal validation test to evaluate reliability of DDN products. Lead corrective and preventive action (CAPA) processes for reliability issues across products. Contribute to or manage a centralized database of reliability test plans, models, and field data to promote reuse and faster decision-making. Present reliability status and risks to executive leadership, influencing design decisions and investment in robustness. Leverage on accelerated test methods to explore design margins and to enable fast selection of concepts. Provide guidance on sample size requirements and duration for reliability testing by utilizing reliability statistics. Act as a champion for reliability culture, fostering a proactive and metrics-driven mindset within cross-functional teams. Analyze data from those optimal validation test to calculate reliability and identify risks or failures. Calculate MTTF based on test to failure evaluation. For identified risks, support definition of mitigation plans and implementation to improve reliability. For identified high risk failure modes and actual failures, support definition of corrective actions and their implementation to improve reliability. Communicate and interact with customer reliability experts to report on reliability analysis. Participate in design reviews and facilitate the reliability section of the design review. Establish a database of reliability tests, models to be re-used across projects. MUST HAVE Bachelor/ Master’s degree in technical discipline (Electrical Engineering, Electronics, Mechatronics) 10+ years of Experience in all aspects of reliability engineering for electronic or mechatronics products from reliability estimation to reliability calculation and risk identification Experience managing engineering teams in cross-functional, multi-site global organizations to drive effectiveness across geographical boundaries and deliver projects with multiple dependencies and constraints. Excellent verbal and written communication skills and the ability to interact professionally with customers, leadership, stakeholders, cross functional teams and subject matter experts. Exceptional analytical, critical thinking, and problem-solving skills and ability to make decisions when presented with a series of challenges, conflicts and constraints. Ability to drive to big picture goals and milestones while valuing and maintaining strong attention to the details. Knowledge on FIT estimation methodology, statistical analysis for reliability calculation such as Weibull-analysis or c2-statistics, application of Bayes theorem, random failure principle, FMEDA, FTA Reliability Engineering training from ASQ, TUV, Reliasoft or equivalent Experience with custom product development, working closely with customers to define mission profile of the end application and optimizing reliability strategy based on customer needs. Experience in running statistical analysis for reliability calculation for mechatronic products. A high curiosity in understanding how systems/product works along with a reverse engineering mindset. Willingness to travel as required, ~20%