You are here

Process Engineer, Avionics Build Reliability

Process Engineer, Avionics Build Reliability

Build and Flight Reliability

SpaceX was founded under the belief that a future where humanity is out exploring the stars is fundamentally more exciting than one where we are not. Today, SpaceX is actively developing the technologies to make this possible, with the ultimate goal of enabling human life on Mars.


The Build Reliability Engineer will ensure the reliability of Avionics flight components and assemblies such Flight Computers, Gyroscopes, Sensors and Video Systems. This individual will evaluate product and process output data to drive improvements in manufacturing and acceptance test quality, and actively represent quality objectives in design and New Product Introduction (NPI) teams.


  • Develop, implement, and continuously improve business processes and policies needed for nonconforming hardware management, configuration management, manufacturing and assembly, product traceability, rocket reusability and maintenance, and other critical business/production systems.

Design for Manufacture and Test of Electro-Mechanical Box Assemblies

  • Each Reliability Engineer will be assigned an Avionics product family (i.e. RF, Power, Flight Computer, Engine Controllers and Navigation Systems) as well as a Work Center (i.e. SMT, Box Assembly, Harness or Integration).
  • Responsible for tracking product/process yields, test and inspection escapes, identifies key characteristics, First Article and Detailed Inspection planning, evaluation of previous non-conformances and lessons learned.
  • Participates in Critical Design Review (CDR) to ensure Design For Quality (DFQ), Design For Manufacturability (DFM), risk quantification, and that appropriate test validation methods have been considered.

Inspection and Test Process

  • Supports new product introduction for PCBAs and mechanical box assembly; quantifies process risk using PFMEA and implements pro-active measures to mitigate this risk (i.e. poka yoke).
  • Performs Gauge R&R to validate test systems used for Acceptance and Qualification Testing of Avionics products.
  • Performs statistical analysis and Design of Experiments (DOE) to qualify new manufacturing processes such as Conformal Coat, Wire bonding and single-arm robotic cells. Implements and tracks SPC.
  • Works with Production Quality inspectors to identify inspections with subjective criteria and automate or eliminate inspection points using creative error-proofing alternates.

Evaluates and analyzes production quality landscape

  • Uses data to make landscape transparent and drive project prioritization. Responsible for ensuring that issues related to product reliability are primary focus.
  • Drives achievement of quality targets through a review hierarchy with appropriate levels of management.

Root Cause and Corrective Action Investigations

  • Leads/Participates in root cause investigations of mechanical assembly process failures exhibited during environmental testing or in-process.
  • Perform structured root cause analysis on a variety of electronic circuits (i.e. RF, high-frequency I/O interfaces, sensors and power systems) to identify the source of failures (design vs. manufacturing) and drive corrective action.

 Issue Ticket Review/Audit/Containment

  • Supports review of all deviations due to non-conformances in respective area.
  • Leads activity to support containment of all suspect product.
  • Leads and coordinates the management of non-conforming hardware.
  • Ensures inspection/test criteria are objective with clear pass/fail criteria.
  • Assesses new processes for safety and product risks.
  • Ensures adherence to QMS policy and procedures within their work center.

 Production Process Audit/Improvement

  • Assesses new processes for safety and product risks.
  • Ensures adherence to QMS policy and procedures within their work center.
  • Develops criteria and builds audits to identify process weaknesses.
  • Ability to create and deliver presentations for IQ/OQ/PQ, PDR/CDR, Air Force EELV, etc.


  • Bachelor’s Degree in electrical, manufacturing, mechanical or material sciences engineering.
  • Minimum 2 years in a quality, manufacturing, or design engineering role.


  • Experience supporting production of complex electro-mechanical, mechanical, or composites systems in high volume work centers and/or during production ramp-up.
  • Knowledge of quality tools such as Lean principles, Six Sigma, 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.
  • Dedicated to adopting a Lean approach to quality without compromising safety or reliability.
  • Programming experience in Javascript, Python, C and SQL.
  • CAD experience (NX/Unigraphics preferred).
  • Hands-on engineer with a passion for continuous improvement and building the best hardware.
  • Demonstrated capability solving complex problems with little to no supervision on schedule as an individual or as a member of an integrated team.
  • Experience in a fast-paced, iterative design environments within the consumer electronics, mobile handset, medical devices, aerospace, marine or automotive industries.
  • Experience with micro electronics manufacturing processes. Experience with automated test methods such as flying probes or bed of nails.


  • Ability to work extended hours, weekends, and offsite as needed. 

Job Location