25 Failure Analysis Engineer Interview Questions and Answers

Failure analysis engineers are responsible for investigating the root cause of component or product failures. They use their knowledge of physics, engineering, and materials science to determine the cause of a failure and develop a plan to prevent it from happening again.

If you’re interviewing for a job as a failure analysis engineer, you can expect to be asked a range of questions about your experience and knowledge. Interviewers will want to know what experience you have in the field, as well as your understanding of the principles of failure analysis. They may also ask about your ability to think on your feet and solve problems.

To help you prepare for your interview, we’ve compiled a list of some of the most common questions asked in interviews for failure analysis engineers. We’ve also included sample answers to help you formulate your own responses.

1. Are you comfortable working with hazardous materials?

The interviewer may ask this question to determine your comfort level with working in a potentially dangerous environment. If you have experience working with hazardous materials, share that information and explain how you handled the situation. If you haven’t worked with hazardous materials before, you can still answer honestly by explaining what you would do if presented with such an opportunity.

Example: “Absolutely. I have extensive experience working with hazardous materials in my current role as a Failure Analysis Engineer. I am well-versed in the safety protocols and procedures necessary to handle these materials safely, including proper storage and disposal of hazardous waste. I also understand the importance of following all safety regulations when dealing with hazardous materials.

I’m confident that I can bring this same level of expertise to your organization. My background includes developing and implementing failure analysis plans for various types of products, from consumer electronics to medical devices. This has given me a strong understanding of how different materials interact and react under certain conditions, which is essential when working with hazardous materials. I have also conducted numerous root cause analyses on failed components to determine the source of the problem and develop solutions.”

2. What are some of the most important skills for a failure analysis engineer to have?

This question can help the interviewer determine if you have the skills necessary to succeed in this role. Use your answer to highlight some of the most important skills for a failure analysis engineer and explain why they are so important.

Example: “As a Failure Analysis Engineer, I believe the most important skills to have are problem solving, critical thinking, and communication. Problem solving is essential in this role because it allows me to identify root causes of failure and develop solutions that prevent future failures. Critical thinking helps me analyze data and draw conclusions from my findings. Finally, effective communication is key for relaying results and recommendations to stakeholders.

In addition to these core skills, I also bring experience with various analysis techniques such as FMEA, Root Cause Analysis, and Reliability Centered Maintenance. My background in engineering principles and practices has enabled me to successfully troubleshoot complex systems and apply corrective actions when needed. Furthermore, I am highly organized and detail-oriented, which enables me to effectively document test results and create comprehensive reports.”

3. How would you go about investigating a product failure if you didn’t have access to the original design plans or materials?

This question is designed to assess your problem-solving skills and ability to work without all the necessary information. It also tests your knowledge of how a product failure investigation should be conducted.

Example: “If I didn’t have access to the original design plans or materials, my first step would be to conduct a thorough visual inspection of the failed product. This would include examining any visible damage and noting any areas that may need further investigation.

Next, I would use specialized testing equipment such as an X-ray machine or scanning electron microscope to analyze the internal structure of the product. This would allow me to identify any structural flaws or material defects that could have caused the failure.

I would also take detailed measurements of the components and compare them to the manufacturer’s specifications. This would help me determine if there were any discrepancies between the actual product and the intended design.

Lastly, I would consult with experts in the field and review any relevant literature related to the product. This would give me additional insight into potential causes of the failure and provide me with more information to work with.”

4. What is the most challenging product failure you have ever investigated?

This question can help interviewers learn more about your problem-solving skills and how you react to challenges. When answering this question, it can be helpful to describe a specific situation that was challenging but also how you overcame the challenge.

Example: “The most challenging product failure I have ever investigated was a complex electronic device. The device had multiple components that were interconnected and it was difficult to determine the root cause of the failure. After extensive testing, I identified several possible causes for the failure, including a faulty component, an incorrect wiring configuration, or a software issue.

To further investigate the problem, I used advanced diagnostic tools such as oscilloscopes and logic analyzers to analyze the data from the device. I also consulted with experts in the field to gain insight into the design and functionality of the device. Through this process, I was able to narrow down the potential causes and eventually pinpointed the exact source of the failure. This allowed me to provide recommendations on how to prevent similar failures in the future.”

5. Provide an example of a time when you identified the root cause of a product failure.

Interviewers may ask this question to assess your problem-solving skills and ability to identify the root cause of a failure. Use examples from previous work experience where you were able to successfully identify the root cause of a product failure.

Example: “I recently had the opportunity to identify the root cause of a product failure while working as a Failure Analysis Engineer. The product was an electronic device that was failing during its testing phase. After conducting extensive research, I discovered that the issue was related to a component in the power supply system. Upon further investigation, I found that the component was not properly rated for the amount of current it was receiving, which caused it to overheat and fail.

Once I identified the root cause of the failure, I worked with the design team to develop a solution. We implemented a new power supply system with components that were correctly rated for the current load. This allowed us to successfully pass all tests and bring the product to market.”

6. If you were unable to determine the root cause of a product failure, how would you proceed?

This question can help interviewers understand how you approach challenges and solve problems. Use your answer to highlight your problem-solving skills, ability to work under pressure and commitment to quality results.

Example: “If I were unable to determine the root cause of a product failure, my first step would be to identify any potential causes. This could include examining the design and manufacturing processes, testing for material defects, or analyzing the environment in which the product was used. Once I have identified possible causes, I would then use various investigative techniques such as reverse engineering, metallurgical analysis, or electrical diagnostics to further investigate the issue.

I also believe that communication is key when it comes to failure analysis. I would reach out to other experts in the field, discuss the problem with colleagues, and review reports from similar failures. Finally, I would document all findings and conclusions so that they can be shared with other team members and stakeholders. By taking these steps, I am confident that I can accurately diagnose the root cause of a product failure.”

7. What would you do if you suspected that a coworker was withholding information during an investigation?

This question can help interviewers assess your interpersonal skills and ability to work with others. In your answer, try to show that you value teamwork and collaboration. Showcase your communication skills by explaining how you would approach the situation in a direct manner.

Example: “If I suspected that a coworker was withholding information during an investigation, my first step would be to approach the situation with respect and professionalism. I would start by asking questions in order to gain more insight into what is going on. I believe it is important to remain open-minded and non-judgmental when dealing with this kind of situation.

I would also take the time to listen carefully to their responses and look for any inconsistencies or discrepancies. If I still felt like something was not being shared, I would then explain why I think they may be holding back and ask if there is anything else they can tell me. Finally, I would document all conversations and findings so that I have a clear record of what has been discussed.”

8. How well do you understand the different types of materials used in the manufacturing process?

The interviewer may ask this question to assess your knowledge of the materials used in manufacturing and how they affect a product’s performance. Use examples from past projects where you had to analyze different types of materials or discuss their properties with other engineers.

Example: “I have a deep understanding of the different types of materials used in manufacturing processes. I am familiar with both traditional and modern materials, including metals, plastics, ceramics, composites, and polymers. I understand how each material behaves under various conditions, such as temperature, pressure, vibration, and chemical exposure. My experience includes analyzing failure modes for components made from these materials, which has allowed me to develop an in-depth knowledge of their properties.

In addition, I have worked closely with manufacturers to identify the best materials for specific applications. This has enabled me to gain a better understanding of the strengths and weaknesses of each material, allowing me to make informed decisions when selecting materials for new projects. Finally, I have conducted extensive research into emerging materials and technologies that could potentially be used in future manufacturing processes.”

9. Do you have experience using computer-aided design (CAD) software?

The interviewer may ask this question to learn more about your experience with the tools and software used in a failure analysis engineer’s job. Use your answer to share which CAD programs you have used in the past, what you liked about them and any skills you gained from using these programs.

Example: “Yes, I have extensive experience using computer-aided design (CAD) software. During my time as a Failure Analysis Engineer, I worked with CAD software to create detailed diagrams and schematics of components and systems. I was also responsible for troubleshooting any issues that arose during the design process. My expertise in CAD enabled me to quickly identify potential problems and develop solutions to address them.

In addition, I am familiar with various types of CAD software, including AutoCAD, SolidWorks, and Pro/Engineer. I understand how to use these programs to create accurate models and simulations, which can be used to analyze failure modes and predict future performance. This knowledge has been invaluable in helping me diagnose complex failures and devise effective corrective actions.”

10. When investigating a product failure, do you have a process you follow to ensure you don’t miss any important details?

An interviewer may ask this question to understand how you approach a task and whether your process is effective. Use your answer to explain the steps you take when investigating product failures, including what you look for during each step of the process.

Example: “Yes, I do have a process that I follow when investigating product failures. First, I collect all relevant data and information related to the failure. This includes any test results, design specifications, or other technical documents. Then, I review the data and identify potential causes of the failure. After this initial assessment, I conduct further tests and analysis to narrow down the possible root cause. Finally, I create a report that outlines my findings and recommendations for corrective action. Throughout this process, I make sure to document every step so that nothing is missed.

My experience as a Failure Analysis Engineer has taught me how important it is to be thorough in these investigations. I understand the importance of not missing any details, which is why I take such care in following my process.”

11. We want to improve our product failure rate. What strategies would you use to identify the root cause of product failures and prevent them in the future?

This question allows you to demonstrate your problem-solving skills and ability to apply them to a real-world scenario. Use examples from previous experience to show the interviewer that you can use critical thinking, creativity and innovation to solve problems.

Example: “As a Failure Analysis Engineer, I understand the importance of identifying and preventing product failures. To achieve this goal, I would use a combination of strategies to identify root causes and prevent future product failures.

Firstly, I would conduct detailed failure analysis on each failed product. This includes examining all components for defects or damage, as well as reviewing any relevant test data and customer feedback. By thoroughly analyzing the failed product, I can determine what caused the failure and develop an action plan to address it.

Secondly, I would work with other departments to review existing processes and procedures. This could include evaluating manufacturing processes, testing protocols, and quality control measures. By understanding how products are made and tested, I can identify potential areas of improvement that could help reduce product failures in the future.

Lastly, I would recommend implementing preventive maintenance programs. These programs involve regularly inspecting and servicing equipment to ensure optimal performance. Preventive maintenance can help identify issues before they become problems, reducing the likelihood of product failures.”

12. Describe your experience with statistical analysis.

The interviewer may ask this question to learn more about your experience with failure analysis and how you apply statistical methods in your work. Use your answer to highlight the specific tools or software you use for statistical analysis, including any certifications you have that allow you to use these tools.

Example: “I have extensive experience with statistical analysis. I am proficient in using a variety of software programs to analyze data, including Excel and SPSS. I have used these tools to perform various types of analyses such as descriptive statistics, regression models, ANOVA tests, and t-tests. I also have experience creating visualizations such as graphs, charts, and tables to present the results of my analyses.

In addition, I have conducted research on failure analysis and how it can be used to improve product quality. My research has included developing methods for analyzing large datasets to identify trends in failure rates and determining root causes of failures. I have also developed predictive models that can help anticipate future problems and prevent them from occurring. Finally, I have presented my findings at conferences and published papers in peer-reviewed journals.”

13. What makes you the best candidate for this position?

Employers ask this question to learn more about your qualifications and how you feel they align with the job. Before your interview, make a list of all the skills you have that are relevant to this position. Think about what makes you unique from other candidates and highlight these skills in your answer.

Example: “I believe I am the best candidate for this position because of my extensive experience in failure analysis engineering. I have been working in this field for over 5 years and have a deep understanding of how to identify, analyze, and prevent failures. My expertise includes root cause analysis, problem solving, and troubleshooting complex systems.

In addition to my technical skills, I also bring strong communication and organizational abilities to the table. I am able to effectively communicate with both internal and external stakeholders to ensure that all parties are on the same page when it comes to resolving issues. Furthermore, I am highly organized and can manage multiple projects at once while still delivering quality results.”

14. Which industries do you have the most experience working in as a failure analysis engineer?

This question can help the interviewer understand your experience level and how you might fit into their company. Use your answer to highlight any skills or experiences that are relevant to this role, such as industry certifications or specific software knowledge.

Example: “I have extensive experience working as a failure analysis engineer in the automotive, aerospace, and medical device industries. I am highly knowledgeable of the unique challenges that each industry presents when it comes to analyzing failures. In the automotive industry, I have worked on projects involving engine components, transmission systems, and other mechanical parts. In the aerospace industry, I have analyzed materials used in aircrafts such as aluminum alloys and composites. Finally, in the medical device industry, I have conducted failure analyses for implantable devices, surgical instruments, and drug delivery systems.”

15. What do you think is the most important skill for a failure analysis engineer to have?

This question can help the interviewer determine your priorities and how you view failure analysis engineering. Your answer should show that you understand what skills are important for this role, but it can also give insight into which of these skills you have yourself.

Example: “As a failure analysis engineer, I believe the most important skill to have is problem-solving. It’s essential for me to be able to identify and analyze problems in order to determine their root cause. This involves using my knowledge of engineering principles and techniques, as well as data analysis skills, to develop solutions that will prevent future failures from occurring.

In addition to problem-solving, I also think it’s important for a failure analysis engineer to have excellent communication skills. Being able to effectively communicate with other engineers, technicians, and management personnel is key in order to ensure that everyone understands the issue at hand and can work together to find a solution. My experience working on complex projects has given me the ability to clearly explain technical concepts in an easy-to-understand manner.”

16. How often do you think failure analysis engineers should update their knowledge and skills?

This question can help interviewers understand how you keep up with the latest developments in your field. Your answer should show that you are committed to learning and growing as a failure analysis engineer.

Example: “As a Failure Analysis Engineer, I believe it is important to stay up-to-date with the latest technologies and industry trends. This means regularly updating my knowledge and skillset in order to remain competitive and provide the best possible service to my employer. To do this, I make sure to attend seminars and conferences related to failure analysis engineering, read relevant publications, and participate in online courses or webinars whenever possible. In addition, I also take advantage of any opportunities for hands-on training that may arise. By staying current on the latest developments in the field, I am able to ensure that my work remains efficient, accurate, and effective.”

17. There is a new product failure every day. How would you prioritize your investigations?

This question can help the interviewer understand how you prioritize your work and manage deadlines. Use examples from previous experience to show that you are organized, detail-oriented and able to meet deadlines.

Example: “When it comes to product failure investigations, I believe that prioritization is key. My approach would be to first identify the most critical failures and prioritize those for investigation. To do this, I would review customer feedback, technical reports, and any other relevant data to determine which failures are having the greatest impact on customers or operations. Once these high-priority issues have been identified, I would then focus my attention on them.

Next, I would break down each issue into its component parts in order to better understand the root cause of the failure. This could involve examining design specifications, materials used, manufacturing processes, and any other factors that may have contributed to the problem. By doing so, I can quickly identify potential areas of improvement and develop solutions to prevent similar failures from occurring in the future.

Lastly, I would document all findings and recommendations in a report that can be shared with stakeholders. This ensures that everyone involved has access to the same information and can make informed decisions about how to address the issue.”

18. How would you go about verifying the accuracy of product failure data?

This question can help the interviewer assess your analytical skills and ability to conduct thorough research. Use examples from past experiences where you verified data accuracy by comparing it with other sources or using statistical analysis tools.

Example: “Verifying the accuracy of product failure data is an important part of my job as a Failure Analysis Engineer. To ensure that I am providing accurate and reliable results, I use a combination of analytical techniques to verify the data.

The first step in verifying product failure data is to review the existing data and identify any discrepancies or inconsistencies. This can be done by comparing the data with other sources such as customer feedback, industry standards, and past reports. Once any discrepancies have been identified, I will then investigate further to determine the root cause of the issue.

Next, I will conduct tests on the products to confirm the accuracy of the data. These tests may include physical inspections, electrical testing, environmental testing, and more. By performing these tests, I can validate the data and make sure it is accurate.

Lastly, I will analyze the data using statistical methods to identify patterns or trends in the data. This helps me to understand how the product failed and what could have caused it. By doing this, I can provide detailed reports to management that are based on accurate and reliable data.”

19. Describe a time when you were able to identify a trend in product failures that allowed you to prevent future ones.

An interviewer may ask this question to learn more about your analytical skills and how you apply them in the workplace. Use your answer to highlight your ability to use data to make decisions that benefit a company’s bottom line.

Example: “I recently worked on a project where I was tasked with identifying trends in product failures. After analyzing the data, I noticed that there were certain commonalities between the failed products. For example, many of them had similar components or materials that were failing at the same rate.

Once I identified these patterns, I proposed changes to the production process and design of the product. By making small tweaks to the manufacturing process and component selection, we were able to reduce the failure rate significantly. This resulted in fewer returns and complaints from customers, as well as increased customer satisfaction.”

20. What do you believe is the most effective way to communicate the findings of a failure analysis to other departments within an organization?

The interviewer may ask you this question to assess your communication skills and how well you can collaborate with others. Use examples from past experiences where you successfully communicated failure analysis findings to other departments or teams within an organization.

Example: “I believe that the most effective way to communicate the findings of a failure analysis is through clear and concise documentation. This should include an overview of the problem, the root cause of the failure, and any recommendations for corrective action. It is also important to provide visual aids such as diagrams or charts to help illustrate the issue and its resolution. Finally, it is essential to ensure that all stakeholders are involved in the communication process by providing them with timely updates on progress and results. By doing this, everyone can be kept informed and have access to the same information.”

21. Are there any particular materials or components that you have experience working with?

The interviewer may ask this question to see if you have experience working with the materials or components that are used in their company. Use your answer to highlight any specific skills, knowledge and expertise you have regarding the materials or components of the company’s products.

Example: “Yes, I have extensive experience working with a variety of materials and components. In my current role as a Failure Analysis Engineer, I have worked with metals such as aluminum, steel, copper, brass, and titanium; plastics such as polyethylene, polypropylene, and nylon; and ceramics such as alumina and zirconia.

I also have experience working with electronic components such as transistors, diodes, capacitors, resistors, integrated circuits, and microprocessors. My expertise in these areas has enabled me to identify the root cause of failure quickly and accurately.

In addition, I am well-versed in various testing methods used for failure analysis, including visual inspection, electrical tests, mechanical tests, chemical tests, and metallurgical tests. This knowledge allows me to develop effective solutions that address the underlying issues causing the failures.”

22. Do you have any familiarity with risk management and quality control processes?

The interviewer may ask this question to assess your experience with failure analysis and how you apply it to a project. Use examples from past projects where you used risk management or quality control processes to ensure the success of a project.

Example: “Yes, I have extensive experience with risk management and quality control processes. In my current role as a Failure Analysis Engineer, I am responsible for identifying potential risks and developing strategies to mitigate them. I also ensure that all products meet the highest standards of quality before they are released to customers. To do this, I use a combination of statistical analysis techniques, root cause analysis, and process improvement methods. My experience has enabled me to develop an in-depth understanding of how to effectively manage risk and maintain high levels of product quality.”

23. What are some of the challenges associated with failure analysis engineering?

This question can help the interviewer gain insight into your ability to handle challenges and overcome obstacles. Use examples from your previous experience to highlight your problem-solving skills, creativity and critical thinking abilities.

Example: “Failure analysis engineering can be a challenging field, but it is also incredibly rewarding. One of the biggest challenges associated with failure analysis engineering is determining the root cause of a particular failure. This requires extensive knowledge and experience in order to understand the complex interactions between components and systems that may have led to the failure. Another challenge is being able to identify potential areas of improvement or design changes that could prevent similar failures from occurring in the future. Finally, there is often a need for quick turnaround times when dealing with critical failures, so having strong problem-solving skills and an ability to work under pressure are essential.”

24. How comfortable are you using various testing equipment and machines?

The interviewer may ask this question to assess your comfort level with using various testing equipment and machines. Use your answer to highlight any experience you have working with these tools and machines, as well as the skills you developed while using them.

Example: “I am very comfortable using various testing equipment and machines. I have extensive experience in the field of failure analysis engineering, which requires me to be familiar with a wide range of testing equipment and machines. During my time as a Failure Analysis Engineer, I have used many different types of test equipment such as oscilloscopes, spectrum analyzers, thermal imaging cameras, and other specialized tools.

In addition, I have also worked with a variety of automated machines for testing purposes. These include robotic systems, 3D printers, CNC machines, and more. I understand how to set up these machines properly, troubleshoot any issues that arise, and interpret the results accurately. My familiarity with these machines has enabled me to quickly identify potential problems and develop effective solutions.”

25. Can you provide examples of reports, presentations, or documents you have written as a failure analysis engineer?

Interviewers may ask this question to learn more about your writing skills and how you present information. When answering, it can be helpful to provide an example of a report or document you have written in the past that helped your team complete a project successfully.

Example: “Yes, I have extensive experience writing reports, presentations, and documents as a failure analysis engineer. For example, I recently wrote a report for a major aerospace company that detailed the root cause of a component failure in their aircraft engine. The report included an overview of the failed component, a description of the testing methods used to analyze the failure, and my conclusions about the root cause of the failure.

I also created several presentations for a large automotive manufacturer on how to reduce warranty costs through improved failure analysis processes. These presentations focused on topics such as identifying common failure modes, developing effective test plans, and analyzing results to determine root causes.

In addition, I have written numerous technical documents outlining best practices for failure analysis engineers. These documents provide guidance on topics such as selecting appropriate test equipment, interpreting data, and documenting findings. They are designed to help other engineers understand the fundamentals of failure analysis and apply them effectively.”