Senior NPI Quality and Reliability Engineer III

Relocation assistance is available for this position.

Who We Are

Stored Energy Systems (SENS) is an award-winning manufacturer of premium quality power conversion products located in Longmont, CO. In business for over 50 years, SENS is the market leader with a proven track record of providing highly reliable battery chargers, DC power systems, and related products to industrial markets. For more information on our company please see our web site at www.sens-usa.com.

View the SENS Product Catalog

Summary

The Senior NPI Quality and Reliability Engineer III leads new product introduction (NPI) and reliability improvement quality activities for SENS power conversion products. This role connects field performance with product development and production readiness, establishing reliability requirements, quality controls, and acceptance criteria that carry into manufacturing. The engineer leads cross-functional problem solving, guides quality planning through launch, and provides limited component-level electrical troubleshooting to support failure analysis. The position serves as a senior technical contributor and mentor across Engineering, Manufacturing, Supplier Quality, and Customer Support.

Responsibilities

New Product Introduction Quality

• Own quality planning for new products and significant design or process changes, defining deliverables, owners, milestones, and acceptance criteria through production launch.
• Translate customer and product requirements into critical quality characteristics, inspection criteria, and test requirements with Engineering and Manufacturing.
• Participate in design failure mode and effects analysis (DFMEA) and facilitate process FMEA (PFMEA); drive closure of prioritized risk reduction actions.
• Develop or coordinate control plans, first-article inspection, measurement system assessments, and process capability studies appropriate to product and process risk.
• Lead quality activities for prototype and pilot builds; evaluate defects, first-pass yield, test coverage, and process consistency, and drive readiness actions.
• Partner with Supplier Quality and Supply Chain to confirm new or changed purchased parts meet qualification and first-article requirements before production ramp.
• Present quality and reliability evidence at production readiness reviews; confirm required verification and validation are complete, escalate open risks, and recommend release through established approval processes.
• Support production handoff and early production monitoring; confirm controlled documentation, training, traceability, and ownership of remaining actions, and update controls from launch lessons.

Product Reliability

• Establish reliability targets and qualification criteria with Engineering based on application requirements, operating conditions, and known failure mechanisms.
• Plan and coordinate reliability testing, including environmental and accelerated life testing where appropriate; evaluate results and verify corrective actions through retesting.
• Analyze field returns, warranty claims, manufacturing defects, and test data to identify failure trends and prioritize improvement projects.
• Lead cross-functional failure investigations and structured problem solving; drive containment, root-cause confirmation, corrective and preventive actions, and effectiveness verification.
• Maintain failure records, reliability metrics, and lessons learned; communicate significant risks and progress to leadership and incorporate findings into new designs and quality controls.
• Mentor engineers and technical personnel in reliability methods and structured problem solving, and recommend test resources needed for assigned programs.

Component Level Electrical Troubleshooting

• Perform targeted component-level troubleshooting on prototypes, production failures, and field returns using schematics, digital multimeters, oscilloscopes, bench power supplies, and electronic loads.
• Reproduce symptoms, isolate faults, and document measurements under established electrical safety and electrostatic discharge (ESD) controls; coordinate advanced circuit analysis with Design Engineering.

Required Qualifications

• Bachelor's degree in Electrical Engineering or a related technical discipline.
• 5+ years of progressively responsible experience in product reliability, NPI quality, quality engineering, design verification, test, or failure analysis within electronics or electromechanical manufacturing.
• Ability to interpret electrical schematics and component datasheets and use common electronic test equipment safely.
• Demonstrated experience supporting NPI through production launch and improving product reliability or manufacturing quality.
• Working knowledge of FMEA, control plans, verification and validation, root-cause analysis, and corrective action.
• Ability to analyze quality and reliability data using Excel or equivalent tools, communicate technical conclusions, and maintain clear investigation and validation records.
• Demonstrated technical leadership, collaboration, mentoring, and management of competing project priorities.
  
  

Preferred Qualifications

• Experience with industrial power conversion products, battery chargers, DC power systems, or related electromechanical assemblies.
• Experience with Weibull analysis, accelerated life testing, design of experiments, measurement system analysis, or process capability analysis.
• Familiarity with IPC-A-610 and electronic assembly workmanship requirements.
• Experience with ISO 9001 quality systems, advanced product quality planning (APQP), or customer-specific launch requirements.
• Experience with statistical analysis or data visualization tools, such as Minitab, JMP, or Power BI.
• ASQ quality or reliability certification, or a master's degree in a relevant engineering discipline.

Location: Longmont, CO

Base Compensation: $105,000 - $155,000 is the projected range of annual base salary for this role depending on the candidate’s overall qualifications and experience.

Bonus: This position is eligible for an annual bonus based on individual and company performance.

Closing Date: November 30th. While we expect to keep the position open through this date, the posting may be extended or closed early based on applicant volume and hiring needs.

Onsite Perks

• Free gym with 24/7 access
• Free Electric Vehicle charging
• Breakfast and Lunch Café
• After hours Grab & Go snacks
• Basketball court
• Walking paths

Benefits

• Paid Time Off
• Paid holidays
• Medical insurance
• Dental insurance
• Vision insurance
• Short-term and long-term disability
• Life insurance
• 401(k) plan with immediate vesting
• Employee referral program
• Tuition reimbursement
• Professional development

At SENS, our culture is rooted in a set of core values that reflect who we are and how we work. In a recent 2025 poll, our employees identified the values that best define us: “Innovative”, “Respectful”, “Inviting”, “Flexible”, “Collaborative”, and “Growth Driven”. Our team describes us as a dynamic, forward-thinking company where everyone has the opportunity to thrive.

We pride ourselves on being an equal opportunity employer, fully dedicated to fostering inclusion and diversity. We welcome all applicants, regardless of race, color, religion, sex, sexual orientation, gender identity, genetic information, national origin, age, disability, veteran status, or any other legally protected characteristic.

We hope you're interested in making a difference with us. Even if you don't feel that you meet every qualification listed in this job description, we still encourage you to apply.