The Staff Reliability Engineer leads product reliability analysis and prediction throughout the product lifecycle. The position applies reliability methods to evaluate DVP&R results, warranty claims, field-performance data, failure modes analysis and risk evaluation. In collaboration with cross-functional team, the role ensures effective execution of reliability processes, drives continuous improvement of reliability tools, and strengthens the integration of reliability principles across the organization.
LI-Hybrid
Key Responsibilities:
Design Validation Plan & Report Support (DVP&R)
- Perform design life predictions and improve life test efficiency for new and existing programs.
- Analyze historical warranty and DVP&R data to assess product risks.
- Correlate design lifetime, validation/accelerated durability test results, and field data to validate customer required lifetime performance
Warranty Analysis
- Conduct and quantify product specific warranty risk evaluations using statistical analysis.
- Analyze warranty claims and warranty returns root causes, to identify improvement opportunities and validate corrective actions.
- Correlate warranty performance and field data to improve reliability prediction accuracy and support design decisions.
- Support escalated field issue investigations with reliability assessments and structured data analysis.
- Identify emerging failure trends to enable early intervention.
Warranty Data Management
- Improve reliability prediction models, simulation methods, and durability test strategies through analysis of warranty, validation, and field-performance data.
- Develop and enhance warranty analytics tools, databases, and Power BI dashboards to support reliability assessments and business decisions.
- Ensure the integrity, quality, and effective use of warranty data to identify trends, assess risks, and improve prediction accuracy.
- Develop and maintain product and customer reliability databases to support warranty forecasting, reliability prediction models, and identification of trends across products and customers.
Training, Coaching and Plant Support
- Provide internal training and coaching on reliability methods and statistical tools.
- Support manufacturing plants with reliability assessments and structured problem-solving methodologies and best practices.
- Lead knowledge-sharing activities to promote lessons learned and the application of reliability best practices across the organization
- Support customer meetings and technical discussions when required.
- Prepare executive-level summaries to support leadership decision-making.
CORE DELIVERABLES
- Reliability risk assessments and life prediction analyses supporting product development and production programs.
- Warranty and field-performance analyses identifying emerging failure trends and risks
- Reliability prediction models and data-driven recommendations support design, validation, and business decisions.
- Product and customer reliability databases providing warranty forecasting, trend analysis, and predictive analytics.
- Reliability dashboards, reports, and analytical tools that improve visibility of warranty and field performance.
- Technical assessments and recommendations for critical field issues, customer escalations, and reliability risks.
- Training materials, coaching programs, and knowledge-sharing activities that strengthen organizational reliability capability.
- Executive-level summaries and presentations supporting leadership decision-making.
What we’re looking for:
- EDUCATION AND EXPERIENCE (Minimum Qualifications)
- Experience with reliability analysis tools and methodologies (e.g., Weibull++, Minitab, JMP)
- Knowledge of warranty processes, field performance analysis, and reliability prediction techniques.
- Experience with statistical analysis, predictive modeling, and warranty forecasting.
- Experience with Power BI, database management, and data visualization tools.
- Working knowledge of DFMEA, Design for Reliability (DfR), and structured problem-solving methodologies (8D, 5 Whys, Root Cause Analysis).
- Experience supporting senior management in a fast paced, metrics driven technical teams.
- Ability to lead small global, cross-functional teams during investigations with strong communication, negotiation, and consensus building skills.
- Demonstrated ability to generate innovative solutions and explore new analytical methods.
- Education, Skills, Knowledge Requirements:
- Hands-on experience with reliability analysis and Weibull tools (e.g., Weibull++, MATLAB, Minitab, JMP).
- Knowledge of warranty procedures and requirements.
- Experience using Six Sigma tools; Lean Green or Black Belt preferred.
- Working knowledge of DFMEA and problem-solving tools (8D, 5 Whys, Quality Alerts, Root Cause Analysis).
- Familiarity with Python programming.
- Experience with Power BI and SharePoint for data visualization and collaboration.
- CORE COMPETENCIES
- Priority Setting
- Motivating Others
- Process Management
- Problem Solving
- Functional/Technical Skills
- Decision Quality
- Ethics and Values
- Customer Focus
- Drive for Results
- Business Acumen
What we believe
- Inclusion-We value diversity in people, ideas, and experiences.
- Integrity- We believe in transparency, authenticity, and depend on each other to deliver what we promise.
- Excellence- We contribute to our developments by seeking knowledge and sharing information.
- Responsibility- We care about our local communities and the global environment.
- Collaboration- We are one BorgWarner.
Safety
This position will adhere to Global Star Safety Program, including safety rules, practices and training as outlined in the BorgWarner PTC Safety Policy Manual, which includes the use of equipment, protective devices, or clothing that the employer requires. This individual will work in manners that stress the importance of preventing accidents and illnesses. He/she must take every precaution reasonable in the given circumstance for the protection of themselves and coworkers. In addition, he/she is responsible for reporting all injuries and/or possible dangerous situations, incidents, or occurrences to the immediate supervisor.
Equal Employment Opportunity
BorgWarner is an equal employment opportunity employer such that all qualified applicants will receive consideration for employment without regard to race, color, age, religion, sex, sexual orientation, gender identity/expression, national origin, disability or protected veteran status.
No Unauthorized Referrals from Recruiters & Vendors
Please note that BorgWarner and any of its affiliated companies does not seek or accept unsolicited resumes or offers from third party recruiters or staffing agencies associated with any published or unpublished employment opportunities. Any unsolicited information sent to BorgWarner will be considered as unencumbered and free from any fee or charge whatsoever. Only members of our Human Resources Team have the authority to engage or authorize recruiting services, which must be agreed upon before the unsolicited resume or offer is received.
Join the company that is creating solutions that support a cleaner, more energy-efficient world.
For more information about BorgWarner, please visit www.borgwarner.com
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