Staff Mechanical Engineer – Continuous Improvement for Mechanical Design & Quality Control

About the role

Responsibilities

• Lead the root cause analysis of mechanical failures using data from diagnostics, hands-on testing, and fundamental analysis of bolted joints or material fatigue life
• Redesign or re-engineer components, fasteners, or assemblies to eliminate failures, reduce costs, or improve serviceability
• Coordinate design engineering, manufacturing, and quality teams to ensure that changes are thoroughly tested and validated with short feedback cycles
• Collaborate with NPI, manufacturing quality, and supply chain teams to ensure solutions are optimized for production, vendor capabilities, and field service
• Predict and prevent failure modes by applying a deep understanding of mechanical system interactions, tolerance stack-ups, and real-world use conditions
• Implement feedback loops from field issues into design standards and engineering processes to continuously improve product quality and reduce recurrence
• Manage internal improvement systems that embed learnings into manufacturing process flow and future design development efforts
• Support the development of service tooling, testing fixtures, or diagnostic aids as needed for improved deployment and serviceability
• Travel to HQ in Menlo Park, CA required once per quarter

Requirements

• BS or MS in Mechanical Engineering or a similar technical field, minimum BS + 11 years mechanical design experience
• Hands-on experience with mechanical design, including analysis of bolted joints, stress analysis, and structural integrity
• Hands on experience with component and system level testing including measurement techniques and data analysis
• Proven ability to use data-driven root cause analysis to solve complex, cross-functional design issues.
• Experience addressing and resolving field and production issues
• Knowledge of DFM/DFA principles and quality system tools (PFMEA, 8D, CAPA, etc.)
• Deep understanding of tolerance stack-ups and the use of CMMs in inspection processes
• Familiar with manufacturing processes including tube swaging, crimping, potting, stamping, sheet metal, hydroforming, welding, machining, and fabrication
• Proficient in SolidWorks or a comparable CAD package; PDM experience preferred
• Experience with structural FEA and/or is a plus
• A passion for building robust, field-ready solutions with high reliability and serviceability