Staff Failure Analysis Engineer

Agility’s commercially deployed humanoids operate alongside teams in warehouses, manufacturing facilities, and distribution centers—tackling physically demanding and repetitive tasks while enabling workers to focus on higher-value work. With industry-leading safety standards and years of proven deployment data, we're pioneering a new era of automation that enhances human potential.

About the Role

We are seeking an experienced Field Failure Analysis Engineer to lead deep-dive technical investigations into electromechanical, hardware, and system-level field failures across deployed Digit fleets. In this role, you bridge field operations, customer deployments, and engineering design teams to rapidly contain field escapes, definitively identify physics-of-failure mechanisms, and drive closed-loop corrective actions (CAPA) back into manufacturing and next-generation architecture.

About the Work

• Drive Deep-Dive Physical & System FA: Lead end-to-end failure investigations on field-returned modules—including high-torque actuators, cycloidal/planetary gearboxes, high-strain cable harnesses, PCBAs, motor controllers, safety sensors (LiDAR/depth cameras), and battery management systems (BMS).
• Telemetry & Log-Driven Triage: Correlate physical failure modes with fleet telemetry data, onboard CAN/EtherCAT bus logs, system crash dumps, and time-series sensor data to reproduce field anomalies in lab environments.
• Own 8D & CAPA Execution: Champion structured problem-solving (8D, 5-Why, Fishbone, FTA) for critical field excursions. Partner cross-functionally with Design Engineering, Manufacturing Quality, and Supplier Quality to drive permanent design-for-reliability (DFR) and design-for-serviceability (DFS) mitigations.
• Rapid Field Containment: Define immediate containment protocols, triage criteria, and inspection work instructions for field technicians and customer-support teams during safety-critical or fleet-wide failure events.
• Manage FA Lab & External Testing Partners: Oversee internal failure analysis lab equipment (oscilloscopes, thermal imaging, digital microscopy, dynamometers) and coordinate advanced external analytical testing (CT scanning, SEM/EDX, cross-sectioning, metallurgical analysis).
• Standardize RMA & Depot FA Workflows: Establish standardized teardown SOPs, failure code taxonomies, and disposition tracking across repair depots and Salem assembly facilities.
• Quality Reporting & Pareto Analytics: Analyze fleet return rates, Mean Time Between Incidents (MTBI), and component failure modes to deliver clear Pareto metrics and technical executive summaries to engineering and operations leadership.

About You

• Education: Bachelor’s degree in Mechanical Engineering, Electrical Engineering, Mechatronics, Systems Engineering, or equivalent practical experience.
• Experience: 6+ years of hands-on failure analysis, field quality, or reliability engineering experience supporting complex electromechanical systems (Robotics, Autonomous Vehicles, EV/Powertrain, Aerospace, or Heavy Industrial Automation).
• Mechatronics Troubleshooting: Demonstrated ability to trace cross-domain issues spanning mechanical stress/wear, electrical signal degradation, motor drive failures, and firmware/sensor interaction.
• Structured RCA Mastery: Practical mastery of 8D, Fault Tree Analysis (FTA), FMEA, and Ishikawa diagrams, with a portfolio of verified corrective actions that eliminated field failure modes.
• Lab Tool Proficiency: Proficiency with bench diagnostic tools (DMMs, high-bandwidth oscilloscopes, logic analyzers, optical microscopy, thermal cameras, torque test fixtures).

Preferred Qualifications

• Experience with Linux environments, ROS, CAN/EtherCAT protocol analyzers, and cloud-based time-series data visualization (e.g., Grafana, Datadog, or custom fleet dashboards).
• Working knowledge of functional safety considerations (ISO 13849, IEC 62061) in industrial automation or mobile robotics.
• Proven background managing third-party destructive/non-destructive testing labs (SEM, EDX, X-ray/CT scan).
• ASQ certification (CQE, CRE) or Lean Six Sigma Green/Black Belt.

Work Environment & Travel

• Based on-site at our Salem, OR facility with regular presence across testing labs, service centers, and assembly lines.
• Travel up to 20% to customer logistics centers, field trial sites, or component suppliers for urgent containment and on-site failure characterization.

Location

• This is an onsite position at our Salem office.

The final salary offered to a successful candidate will be dependent on several factors that may include but are not limited to: job-related knowledge, skills, and experience. Agility Robotics is a multi-state employer and this salary range may not reflect positions who work in other locations. These ranges may be modified in the future.

Anticipated Base Salary Range $147,000 — $191,000 USD

In addition to base pay, our competitive total rewards package consists of the following for full-time employees:

• 401(k) Plan: Includes a 6% company match.
• Equity: Company stock options.
• Insurance Coverage: 100% company-paid medical, dental, vision, and short/long-term disability insurance for employees.
• Benefit Start Date: Eligible for benefits on your first day of employment.
• Well-Being Support: Employee Assistance Program (EAP).
• Time Off:
  • Exempt Employees: Flexible, unlimited PTO and 12 company holidays, including a winter shutdown.
  • Non-Exempt Employees: 10 vacation days, paid sick leave, and 12 company holidays, including a winter shutdown, annually.
• On-Site Perks: Catered lunches four times a week and a variety of healthy snacks and refreshments at our Salem and Pittsburgh locations.
• Parental Leave: Generous paid parental leave programs.
• Work Environment: A culture that supports flexible work arrangements.
• Growth Opportunities: Professional development and tuition reimbursement programs.
• Relocation Assistance: Provided for eligible roles.
• Annual Discretionary Bonus: Provided for eligible roles.

All of our roles are U.S.-based. Applicants must have current authorization to work in the United States.