Sr. Systems Reliability Engineer

At Zone 5 Technologies, we're redefining what's possible in precision weapons and unmanned aircraft systems (UAS). Our team of engineers and innovators are developing cutting-edge autonomous solutions to deliver affordable and scalable precision weapons, interceptors, and UAS.

We're building the next generation of munitions and unmanned systems for the United States and its allies. If you're driven by hard problems, energized by rapid innovation, and ready to make an impact on defense technology, you belong here.

We are seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle. This role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. You will engage directly with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews.

Key Responsibilities:

Reliability & Maintainability Architecture

Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C (Reliability, Availability, Maintainability-Cost) Rationale Report

Lead Failure Modes, Effects, and Criticality Analysis (FMEA/FMECA), Fault Tree Analysis (FTA), and Reliability Block Diagram (RBD) development across system architecture

Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support R&M requirements analysis and trade studies

Draft Reliability Predictions (per MIL-HDBK-217 and related methods) and Maintainability Analyses; maintain traceability between R&M requirements, predictions, and demonstrated performance

Lead Reliability-Centered Maintenance (RCM) and Level of Repair Analysis (LORA); support Testability and Built-In Test (BIT) analysis

Data, Documentation & Test Planning

Establish and own the Failure Reporting, Analysis, and Corrective Action System (FRACAS); maintain closed-loop failure data collection and trending from design through test, production, and sustainment

Develop Failure Definitions and Scoring Criteria (FDSC) and reliability test plans tied to program milestones

Lead reliability growth planning and execution of reliability growth and demonstration testing, including Environmental Stress Screening (ESS) and HALT/HASS where applicable

Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments

Develop technical documentation including R&M standards, specifications, procedures, and user guides

Review ground test, flight test, and live-fire test data to confirm R&M requirements compliance

Customer Engagement & Reviews

Serve as primary point of contact with customers on R&M matters

Present R&M analyses, RAM-C Rationale Report updates, and risk posture at Milestone Reviews (A/B/C) and design reviews (PDR, CDR, TRR, PRR)

Lead Reliability Scoring Conferences and Corrective Action Boards (CAB) with customer participation

Coordinate responses to customer R&M data item deliverables and support In-Service Reviews

Risk Management & Process Improvement

Lead Root Cause and Corrective Action (RCCA) investigations for failures identified through FRACAS

Host corrective action reviews and ensure lessons learned are implemented across the program

Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence and shelf-life and aging surveillance considerations

Apply digital engineering and AI-enabled tools (predictive maintenance, digital twins, automated FRACAS analytics) to R&M processes

Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards

Basic Qualifications:

7+ years as a Reliability Engineer, R&M Engineer, or equivalent reliability-critical engineering role

Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics

Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards

Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure

Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening

Experience engaging with customers on R&M reviews and milestone/design reviews (PDR, CDR, Milestone B/C)

Strong system architecture knowledge and R&M requirements decomposition and allocation

Extensive FMEA/FMECA, FTA, and RBD experience

Failure investigation with proven corrective action implementation

Technical writing for R&M program plans, rationale reports, procedures, and documentation

Design review experience (PDR, CDR, MRR) with strong presentation skills

Data collection, analysis, and trending for R&M metrics

U.S. Citizenship

Preferred Qualifications:

Master's degree in engineering or related field

10+ years progressive R&M experience

ASQ Certified Reliability Engineer (CRE) or equivalent certification

DoD or Navy R&M programs experience, aligned with SECNAV Reliability and Maintainability Engineering guidance

Quantitative reliability growth modeling (e.g., Crow-AMSAA) and Weibull analysis

Maintainability, Testability/BIT, LORA, and RCM experience

Missile, hypersonic, or munitions systems experience, including all-up-round reliability, environmental stress screening, and shelf-life/stockpile surveillance programs

Digital engineering and AI-enabled R&M tools (predictive maintenance, digital twins, automated FRACAS analytics)

Active U.S. Security Clearance or ability to obtain

Level IV - $148k - $180k Level V - $180k - $219k Pay range for this role $148,000 — $219,000 USD

What's in it for you:

Benefits:

Competitive total compensation package

Comprehensive benefit package options include medical, dental, vision, life, and more.

401k with company-match

3 weeks of paid time off each year

40 hours of sick time

12 annual company holidays

Why Join Zone 5 Technologies?

Innovative Environment: Work on cutting-edge technology that is shaping the future of defense and aerospace.

Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what’s possible.

Career Growth: Opportunities for professional development and career advancement.

If you are passionate about unmanned aircraft technology and want to be a part of a dynamic and growing company, we would love to hear from you. Apply today and join the Zone 5 Technologies team!

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Zone 5 Technologies is a federal contractor and participates in E-Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E-Verify system. Learn more about your rights and responsibilities under E-Verify: https://www.e-verify.gov .