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 environment. 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.
