Engineer/Senior Reliability Engineer

1.Role Overview We are looking for an experienced Senior Reliability Engineer to join our RAMS (Reliability, Availability, Maintainability, and Safety) team within the LRU Design and Development division. The role is central to the end-to-end product development lifecycle (PDLC) from concept and requirements through design, verification, qualification, and in-service support — across hardware, software, firmware, and mechanical disciplines for avionics, defence electronics, and weapon system The Senior Reliability Engineer will lead reliability analysis activities, interface with system design and QA teams, and be the primary technical authority for RAMS documentation submitted to customers and regulatory authorities. This role directly supports the company's AS9100 Rev D quality management obligations and DO-254/DO-178C programme compliance. 2. Key Responsibilities 2.1 Reliability Prediction and Analysis Lead and execute reliability predictions at component, board, and LRU level using Parts Stress and Parts Count methods per MIL-HDBK-217F N2, MIL-HDBK-217 Plus, and MIL-HDBK-338B. Calculate Failure Rate () and Mean Time Between Failure (MTBF) for avionics LRUs, weapon systems, and defence electronic assemblies. Perform reliability predictions at all PDLC phases: concept, PDR, CDR, and qualification — updating analysis as design matures. Develop and maintain RAMS Plans, Reliability Prediction Reports, and supporting reliability data packages for customer and regulatory submissions. Assess operating environment effects (temperature, vibration, humidity, altitude) on component failure rates and apply appropriate derating per MIL-STD-975 and company derating standards. 2.2 FMEA / FMECA / FMES Lead and perform Failure Mode and Effects Analysis (FMEA) and Failure Mode Effects and Criticality Analysis (FMECA) per MIL-STD-1629A and ARP4761A for avionics, weapon systems, and electronic LRUs. Conduct Failure Mode and Effects Summary (FMES) analysis and ensure traceability to system-level safety requirements and Functional Hazard Assessments (FHA). Assign criticality rankings (Severity Category and Probability Level) and verify that mitigation actions are reflected in design and test documentation. Participate in and lead Design Review Board (DRB) meetings; present FMEA findings and risk dispositions to Engineering team and QA Manager. Ensure FMEA updates are performed at each V-Model phase gate and residual risk is reviewed against AS9100 Cl. 6.1 risk acceptance thresholds. 2.3 Fault Tree Analysis (FTA) Develop and maintain Fault Tree Analysis (FTA) models for avionics systems and weapon systems per MIL-HDBK-338B guidelines. Perform qualitative and quantitative FTA to identify single-point failures, common-cause failures, and dominant failure contributors. Align FTA results with system safety requirements and DAL/SIL assignments; ensure FTA evidence is included in DO-254 / DO-178C data packages. Present FTA results to system and safety stakeholders; track corrective actions through to closure. 2.4 Reliability Block Diagram (RBD) Modelling Develop and maintain Reliability Block Diagrams (RBDs) for avionics and weapon systems to model series, parallel, and redundant architectures. Calculate system-level MTBF, availability, and mission reliability from RBD models; assess impact of redundancy and design changes on system reliability targets. Maintain RBD models in Windchill Risk & Reliability, RAM Commander, Reliasoft, or Item Toolkit as required by programme. 2.5 Safety Assessment (AS9100 / ARP4761A) Support and lead safety assessment activities per ARP4761A including Functional Hazard Assessment (FHA), Preliminary System Safety Assessment (PSSA), and System Safety Assessment (SSA). Ensure reliability and safety evidence satisfies AS9100 Rev D Clause 6.1 (risks and opportunities) and Clause 8.1 (operational planning and control). Contribute to the Risk Register — identifying, assessing, and tracking reliability and safety risks at each V-Model phase gate per the programme Risk Management Plan. Support Design Assurance Level (DAL) and Safety Integrity Level (SIL) assignments and verify design compliance through analysis and test evidence. 2.6 RAMS Documentation and Reporting Author and own the following programme-level RAMS documents: RAMS Plan, Reliability Prediction Report, FMEA/FMECA Report, FTA Report, RBD Model Report, MTBF Summary, Safety Assessment Summary. Ensure all RAMS documents are placed under Configuration Management (CM) and reviewed at each phase gate per the Document Control procedure. Prepare and present RAMS status at programme reviews (PDR, CDR, TRR, FRR) and customer / authority audits. Interface with Quality Assurance to ensure RAMS outputs satisfy AS9100 Rev D Clauses 8.3, 8.5, and 9.1. Support Stage of Involvement (SOI) audits for DO-178C and DO-254 programmes as RAMS technical authority. 2.7 Tools and Software Operate and deliver analysis using: Windchill Risk & Reliability, RAM Commander, Reliasoft Block Sim / Weibull++, and Item Toolkit. Maintain analysis databases and model files under version control; ensure all tool outputs are reproducible and auditable. Evaluate and recommend reliability analysis tools appropriate to programme needs; support tool qualification activities for DO-178C TQL compliance if required. 3. Required Qualifications and Experience Education Bachelor's degree (BE / B.Tech) in Electronics & Instrumentation Engineering, Electronics & Communication Engineering, Electrical Engineering, Aerospace Engineering, Mechanical Engineering or a closely related discipline. Diploma in a relevant engineering discipline with commensurate experience will be considered. Experience Minimum 6 years of hands-on RAMS engineering experience in aerospace, defence, or avionics product development, with at least 2 years in a senior or lead role. Demonstrated experience on LRU-level reliability analysis — from Requirements phase through Qualification — in a V-Model or ARP4754A-aligned development process. Experience on at least two of the following programme types: Avionics LRU, Weapon System Electronics, Radar/EW Systems, Defence Communication Systems, UAV / UAS Systems. Technical — Mandatory Reliability prediction per MIL-HDBK-217F N2 (Parts Stress and Parts Count methods) — advanced proficiency. FMEA / FMECA per MIL-STD-1629A and ARP4761A — lead-level proficiency. FTA — qualitative and quantitative — per MIL-HDBK-338B. RBD modelling for system availability and mission reliability. MTBF calculation, failure rate allocation, and reliability budget management. RAMS Plan and report authorship for customer-deliverable documentation. Proficiency in at least two of: Windchill Risk & Reliability, RAM Commander, Reliasoft (BlockSim / Weibull++), Item Toolkit. 4. Desirable Skills and Experience Experience at a Defence Public Sector Undertaking (DPSU) — ADA, DRDO, BEL, HAL, ISRO — or Tier 1 defence electronics company. Exposure to AMCA, Tejas, or comparable Indian defence aviation programmes. Certification or formal training: CRE (Certified Reliability Engineer — ASQ), or equivalent. Hands-on experience with PCB-level reliability analysis, including component derating verification and thermal analysis correlation with reliability predictions. Experience with system-level reliability allocation from platform requirement down to LRU / sub-LRU level. Familiarity with Weibull distribution analysis and life data analysis for fielded systems. Exposure to Reliability-Centred Maintenance (RCM) or Preventive Maintenance analysis.