Staff Electrical Sustaining Engineer

Staff Electrical Sustaining Engineer Department: Electrical Engineering / Product Sustaining Reports To: Engineering Manager – Hardware Engineering Location: On-site Position Summary We are seeking an experienced and highly skilled Staff Electrical Sustaining Engineer to provide technical leadership and ownership of mature electrical hardware products throughout their post-launch lifecycle. In this role, you will serve as a subject matter expert and technical lead for complex sustaining engineering initiatives, including component obsolescence mitigation, value engineering, product reliability improvements, root-cause failure analysis, and regulatory compliance updates. You will work closely with Manufacturing, Quality, Supply Chain, Firmware/Systems Engineering, and other cross-functional teams to solve complex technical challenges and ensure electrical designs maintain high standards of quality, reliability, performance, cost effectiveness, and manufacturability. The Staff Engineer will also provide technical guidance and mentorship to other engineers and help establish best practices for sustaining and lifecycle engineering. Key Responsibilities Product Lifecycle Support & Technical Leadership Serve as a technical lead and subject matter expert for electrical hardware throughout the post-release product lifecycle, from NPI handoff through end-of-life. Lead complex sustaining engineering initiatives involving product reliability, component obsolescence, cost reduction, manufacturability, and product performance. Design, modify, test, and validate printed circuit board assemblies (PCBAs) to address end-of-life (EOL) components, cost-reduction initiatives, performance issues, and reliability enhancements. Lead engineering change activities (ECO/ECN), including component selection, schematic updates, PCB layout changes, technical risk assessments, validation strategies, and complete documentation packages. Provide technical guidance and mentorship to engineers and cross-functional teams on electrical design and sustaining engineering issues. Identify opportunities for long-term product and process improvements and drive solutions across multiple products or platforms. Failure Analysis & Root Cause Determination Lead complex electrical root-cause investigations using methodologies such as 8D and 5-Why for field returns, factory yield issues, supplier quality issues, and systemic product failures. Develop structured troubleshooting and failure-analysis strategies for complex analog, digital, power, and microcontroller-based circuitry. Utilize advanced bench test equipment, including oscilloscopes, logic analyzers, spectrum analyzers, signal generators, and other diagnostic tools. Collaborate with Quality Engineering, Manufacturing, and other stakeholders to develop and implement permanent corrective and preventive actions (CAPA). Analyze recurring failure trends and drive design or process improvements to prevent recurrence. Component Engineering & Supply Chain Support Provide technical leadership in managing component obsolescence, supply-chain risks, and lifecycle issues across electrical product platforms. Monitor bills of materials (BOMs) for component obsolescence, single-source vulnerabilities, lead-time risks, and cost-reduction opportunities. Identify, evaluate, test, and qualify alternate components and redesign solutions to maintain manufacturing continuity. Assess technical risks associated with component substitutions and determine appropriate validation requirements. Partner with Supply Chain, suppliers, and contract manufacturers (CMs) to resolve complex component and manufacturing issues. Support strategic component selection and standardization efforts across products where appropriate. Design Verification & Compliance Define and execute design verification strategies for electrical hardware modifications, including functional, performance, reliability, and environmental testing. Lead or support environmenta…

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