What is Failure Analysis?
Failure Analysis is a step-by-step process of determining the reason for a particular machine or equipment failure by way of checking, identification, and examination. It means conducting a test within the system and perform a maintenance check that leads you to a conclusion. A failure analysis takes place to prevent further damages.
How is Failure Analysis used?
Zippia reviewed thousands of resumes to understand how failure analysis is used in different jobs. Explore the list of common job responsibilities related to failure analysis below:
- Implemented ISO and ASTM test methodologies, and developed internal methods of characterization and failure analysis for specific applications.
- Carried out material characterization and failure analysis of exhausted catalyst beds.
- Evaluated performance and conducted failure analysis of products and materials.
- Performed failure analysis to improve product performance and quality.
- Conducted failure analysis and recommended corrective and preventive actions.
- Managed forensic failure analysis projects and supervised technicians.
Are Failure Analysis skills in demand?
Yes, failure analysis skills are in demand today. Currently, 4,431 job openings list failure analysis skills as a requirement. The job descriptions that most frequently include failure analysis skills are senior materials engineer, materials process engineer, and failure analysis technician.
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What jobs can you get with Failure Analysis skills?
You can get a job as a senior materials engineer, materials process engineer, and failure analysis technician with failure analysis skills. After analyzing resumes and job postings, we identified these as the most common job titles for candidates with failure analysis skills.
Senior Materials Engineer
Job description:
As a senior material engineer, you have to work with different materials, including construction products such as glass or polymers. You also have to know the materials and look for eco-friendly solutions. As a senior material engineer. You also have to manage a developmental team and talk about the new aspects of the work with your juniors. You should understand the design process to make sure that the material is perfect and meets the organization's needs.
- Failure Analysis
- Aerospace
- Project Management
- Polymer
- ASTM
- R
Materials Process Engineer
Job description:
Materials Process Engineers are licensed engineers who develop different materials, usually for research or production purposes. They may create new materials derived from existing compounds and materials. Materials Process Engineers must document the processes involved in creating these new materials. They would then study the different elements and specifications of this new material. This would help industries that may need a similar material gauge, whether applicable in their area. Material Process Engineers also work on finding new ways to use existing materials. This would help increase the value of the material since there are more and practical uses for it.
- Failure Analysis
- Material Properties
- Process Specifications
- Engineering Drawings
- DOD
- Data Analysis
Failure Analysis Technician
- Troubleshoot
- Test Equipment
- Failure Analysis
- Sample Preparation
- Assembly Line
- Sectioning
Component Engineer
Job description:
A component engineer monitors, tests, and evaluates different kinds of components in a particular production line. A component engineer is essential in a company that uses the assembly line process of manufacturing as each component must perform efficiently to avoid disruption in the production process. The component engineer is expected to provide reports about each production component, identify areas that need improvements or repairs, and suggest upgrades whenever applicable and necessary.
- Failure Analysis
- DFMEA
- Dvp R
- Obsolescence
- Electrical Components
- Capacitors
Metallurgist
Job description:
A metallurgist is responsible for producing metal items and resources to create components used for large manufacturing and industrial production. Metallurgists operate various machine tools and equipment, requiring them to have a strict adherence to the workplace's safety protocols and regulations to prevent potential hazards and operational delays. They also identify cost-efficient methods for the processes without compromising high-quality standards and business requirements. A metallurgist conducts troubleshooting and enhances technical solutions for production and manufacturing discrepancies.
- Continuous Improvement
- Failure Analysis
- Aerospace
- Heat Treat
- Data Analysis
- Aluminum
Senior Process And Quality Engineer
- Product Quality
- ISO
- Sigma
- Failure Analysis
- Data Analysis
- FMEA
Metallurgical Engineer
Job description:
A metallurgical engineer is responsible for evaluating the chemical and physical properties of alloys and metallic materials to be used for construction and other industrial purposes. Metallurgical engineers also design metals for automobile upgrades and designing alloys for electronics. They create cost-reduction initiative reports and improve extraction methodologies, supervising quality control procedures for high-quality deliverables. A metallurgical engineer inspects the quality of tools and equipment for the operations, strictly adhering to the safety standards and protocols of the organization to avoid potential hazards and delays in the workplace.
- Aluminum
- Failure Analysis
- Corrective Action
- Technical Support
- Continuous Improvement
- ISO
Material Engineer
Job description:
Materials engineers are responsible for developing, processing, and testing materials used to create a wide variety of products. These professionals study and evaluate the properties and structure of different materials, including plastics, metal, ceramics, and composites, to create new products. They also perform other tasks that include providing technical advice on suitable materials, diagnosing faults, and providing advice on planning and conducting inspections, repairs, and maintenance. Additionally, they may also oversee the work of other scientists like technicians and evaluate the technical and economic factors surrounding the design aspects of products.
- DOD
- Failure Analysis
- Data Analysis
- CAD
- ASTM
- Material Properties
Failure Analysis Engineer
Job description:
A failure analysis engineer is responsible for conducting quality control checks on operational business processes, identifying inconsistencies and errors, and writing recommendations to address failures and increase efficiency. Failure analysis engineers analyze incident reports of operational issues, assisting the technology team in designing high-performing software applications and network systems to support business functions and requirements. They also support the end-users in resolving issues, writing resolution, and creating instructional manuals for reference. A failure analysis engineer should have excellent technical skills, as well as intensive knowledge of engineering products and services.
- Corrective Action
- Failure Analysis
- Data Analysis
- Test Equipment
- Failure Analysis Techniques
- IC
Quality/Reliability Engineer
Job description:
Quality training managers are business professionals who evaluate the development and growth needs of employees and their company. The managers develop, facilitate, and oversee the training programs for employees. They focus on how to translate the development for performance enhancement and productivity growth. Part of their job is to assess corporate needs and enforce plans for training and development. They understand the needs and requirements of the customers so they can develop effective processes for quality control among employees.
- Product Quality
- Statistical Analysis
- Corrective Action
- Failure Analysis
- Quality Standards
- Data Analysis
How much can you earn with Failure Analysis skills?
You can earn up to $107,546 a year with failure analysis skills if you become a senior materials engineer, the highest-paying job that requires failure analysis skills. Materials process engineers can earn the second-highest salary among jobs that use Python, $90,788 a year.
| Job title | Average salary | Hourly rate |
|---|---|---|
| Senior Materials Engineer | $107,546 | $52 |
| Materials Process Engineer | $90,788 | $44 |
| Failure Analysis Technician | $51,189 | $25 |
| Component Engineer | $84,771 | $41 |
| Senior Component Engineer | $124,184 | $60 |
Companies using Failure Analysis in 2025
The top companies that look for employees with failure analysis skills are Intel, EFI Global, and Apple. In the millions of job postings we reviewed, these companies mention failure analysis skills most frequently.
Departments using Failure Analysis
| Department | Average salary |
|---|---|
| Engineering | $97,528 |
3 courses for Failure Analysis skills
1. FMEA: Failure, Modes, Effects, Analysis
The FMEA (Failure, Modes, Effects, Analysis) tool is by far one of the best root cause analysis tools out there. As a tool, you can deploy this in both a reactive and proactive way. You can use it to identify what has gone wrong, why it has gone wrong and what potentially you could do to fix this for the longer term. Equally, if you are looking to build out a new process or reengineer and existing one and you want to know what COULD go wrong, the FMEA can do just this. Therefore, this could will educate you on how to use this tool effectively in a range of scenarios. In this course, we will cover:- The fundamentals of the FMEA (what the FMEA is, its purpose and importance etc.)- What root cause analysis is.- How and when you should use the tool.- A breakdown of each section of the tool and how to deploy them.- The overall process of how to build, deploy and implement the findings from an FMEA. - Real life examples of how I have deployed FMEAs in multiple industries and businesses. At the end of this course, you will be able to effectively deploy this fantastic tool in organisations large and small, in services and manufacturing, in your team and across your business...
2. Design Failure Mode Effect Analysis - Concepts & Practice
Design Failure Mode Effect and Analysis (DFMEA) is a very important tool for the design engineer to develop designs which are reliable and safe. This course will take you through the concepts and process of developing a DFMEA. What the course will cover? Need for DFMEADefining failure modesCause and Root cause analysis using Fishbone diagramsEvaluation of Risk - Severity, Occurence and DetectionWhat is Design prevention control and Design detection control / Design verification Grading of severity, occurence and detectionThe systematic process of DFMEAWhat is B diagram and how to prepare B diagram with multiple examplesWhat is P diagram and how to prepare P diagram with multiple examplesDFMEA walkthrough of a Bicycle Exercises for learning by doing. The course is well suited for Mechanical design engineers or aspiring students who want to learn how to design effectively and consider possible failure modes. The class focusses on the concepts and underlying reasoning rather than a descriptive approach. Developing a good DFMEA is critical for complex system engineering work and hence its a key skill to develop for career growth and innovation...
3. Risk Management using Failure Modes Effects Analysis (Ed-2)
SECOND EDITION (2019)Key ChangesIncludes case study examples for Manufacturing, Transaction Processing, Banking, Info SecurityCovers Update on AIAG VDA 2019 FMEA Revision Is a glorious failure is better than a petty success? I'm all for the petty success. A glorious failure leads to nothing; a petty success may lead to a success that is not petty - Arnold Bennett. Every action or in-action in Business involves a potential risk. As a manager of a process, an entrepreneur or a sales manager, you can scoop up success and avoid failures with your tact and vigil. But that will consume you energy and time, leaving you exhausted. Instead a systematic approach to identifying and managing potential issues in your business processes can mean better & consistent business results and 'peace of mind'. The aim of this course is to allow you to understand the foundation skills in Risk Management beyond today's hype and buzzwords-and describes how an entrepreneur, business manager can turn their firefighting efforts into proactive actionable insights. A novice to risk management will equally benefit through this course. Unlike many foundation course, this course quickly deep dives to a Risk Management Tool used by NASA called Failure Modes & Effects Analysis (FMEA) and shows how best to apply it to specific business problems and opportunities within their organization. There is more than 1 reason to consider this course: Receive FMEA Certification on successful completion of project work (details included)Free FMEA Template and Step-by-Step instructions covered in detailExamples for various industries including Manufacturing and Services includedBy the end of the course, you will be able to apply the FMEA to any specific situation of your process or business and effectively eliminate/reduce associates risks by carrying out the following steps: Proactively identify all potential issues across the business Analyze impact of the each issue, its occurrence & existing control mechanisms Prioritize risk that need immediate actionSystematically plan response/mitigation planImplement and reassessMonitoring and control risks ongoing basis...