Job Description: Design for Reliability (DFR) Engineer

Experience Required: Minimum 5 years in Design for Reliability

Domain Preference: Medical Devices (preferred but not mandatory)

Job Type: Contract

Location: Bangalore

Role Summary

We are seeking an experienced Design for Reliability (DfR) Engineer with strong analytical, testing, and PhysicsofFailure (PoF) modelling skills to support the design and development of highreliability products. The ideal candidate will be capable of driving reliability activities endtoendincluding test planning, accelerated life testing, statistical modelling, rootcause analysis, and robust documentationwithin a regulated workplace. Experience in the medical device industry is highly preferred.

Key Responsibilities

1. Field Data Analytics & Statistical Modelling

Perform field return data analysis using Weibull, Exponential, Lognormal, Chisquare and other lifedata distributions.

Develop failure rate predictions and reliability growth assessments.

Identify dominant failure modes and drive corrective actions.

2. PhysicsofFailure (PoF) Modelling

Apply PoF-based reliability models such as:

o Temperature cycling fatigue (CoffinManson, NorrisLandzberg)

o Solder joint fatigue / electronics wearout

o Arrhenius and Eyring acceleration models

o Cumulative damage & stresslife (SN) methodologies

o Humidityrelated degradation models (Pecks model)

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

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

3. Mission Profile Development & Reliability Test Protocols





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

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

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

4. Test Execution & Data Analysis

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

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

Analyze test results and correlate with PoF and statistical models.

5. Documentation & Reporting

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

Ensure all documentation meets medical device regulatory expectations

Maintain version-controlled reliability documentation within PLM systems.

6. Fixtures, Jigs & Test Setup Development

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

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

7. Reliability Analyses (Electronics & System Level)

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

Provide recommendations for component selection, thermal management,



and reliability improvement.

Support DFMEA / PFMEA activities as needed.

8. Software Tools & Data Management

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

or

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

Maintain accurate and traceable recording of all test data.

9. Project Planning & Deliverables

Develop reliability deliverable plans aligned with product development phases.

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

10. Data Recording & Traceability

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

Maintain compliance with quality systems and regulatory requirements.

Qualifications

Must Have

Bachelors or Masters degree in, Electronics, Biomedical, Reliability Engineering, or related fields.

5+ years of handson experience in Design for Reliability.

Strong statistical modelling and PoF modelling expertise.

Experience designing and running HALT/ALT/Life Tests.

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

Proficiency in ReliaSoft or Windchill.

Preferred

Power BI Experience

VBA Macro

Soft Skills

Excellent problemsolving skills and attention to detail.

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

Ability to manage multiple tasks and deliver on time.

Proactive mindset focused on prevention and design robustness.

📌 Design for Reliability (DFR) Engineer (Contract)
🏢 Saaki Argus And Averil Consulting
📍 India