Engineer- Reliability IV USA

Job Description

First Solar reserves the right to offer you a role most applicable to your experience and skillset.

Basic Job Functions:

This position is responsible to support Reliability and Durability programs associated with the First Solar PV plants related to DC, AC, Power Conversion and Grid interconnection systems. Responsible to build/enhance our confidence in predicting the long-term product performance, reliability and service life of our power plants and components, maintain any required and/or appropriate quality/product certifications while ensuring supplier product/process issues do not negatively impact our business.

Responsible for implementing and executing core reliability activities such as building reliability models, generating reliability predictions of systems, conducting sensitivity analysis, model optimization, goal allocation & apportionment, maintainability/availability/throughput analysis, predicting failure rates and maintenance strategies, developing total cost of ownership models etc.

This position is responsible for the development and implementation of new techniques and methods to further First Solar's reliability program. Responsible for evaluation of new tools and their development by working with suppliers to enhance and improve the tool's usefulness and accuracy. Interfaces with O&M, Warranty and technology groups to integrate their needs into System Reliability's workflow and rudiments. Operates independently working with the highest levels of management and technology specialists on projects and current issues.

Education/Experience:

• Bachelor in Reliability/Electrical/Electronic engineering required.
• Master's degree preferred or equivalent combination of education and experience.
• Certified Reliability Engineer (CRE) credentials preferred.
• Requires 7-10 years previous experience in Systems Reliability Modeling, Reliability Predictions related work in PV Energy/Utility/Electronics/Telecommunication or other relevant industry.
• Requires 5+ years demonstrated experience in Reliability Predictions, Apportionment/Allocation, RBD modeling, FMEA/FTA application, Markov Analysis, Availability/Throughput analysis, maintainability, cost and value optimization and resource allocation work.
• Minimum 3-year quality background in a utility or energy related industry required.

Required Skills/Competencies:

• Strong Electrical and Reliability Engineering background with adequate mathematical and statistical analysis skills required to conduct reliability predictions, ability to identify appropriate failure information from various sources, allocation and apportionment of goals, reliability/ maintainability/ availability analysis, throughput calculation, resource allocations, life cycle cost analysis using Reliability Block Diagrams (RBD) of PV power plants required.
• Demonstrated ability to Perform reliability prediction analysis and design trade-off comparisons as to their effect on reliability of the system required.
• Experience Identifying or developing time-to-failure distributions for new components or modified COTS and model numbers required. Ability to utilize these distributions to determine optimal maintenance strategies and periodicities and develop 'templates' for O&M to use in developing and revising PM as well as warranty strategies.
• Demonstrated Experience in utilizing FMEA's, Fault Tree Analysis (FTA) to support troubleshooting and problem solving of plant throughput/downtime issues.
• Experience with integrating reliability analysis with financial models using simulation software such as RENO or GoldSim.
• Experience with developing methods for competitor benchmarking based on availability, maintainability costs, obsolescence risk, climactic differences etc.
• Demonstrated experience with Reliability tools (Weibul++, ALTA, BlockSim, XFMEA, Lambda Predict) & Statistical software (Jmp, Minitab), Microsoft Office tools, Databases, and DataMining tools required.
• Knowledge of reliability growth techniques in large scale power electronics and electrical power systems design, component selection, protection, etc. Good understanding of power electrical/electronics system simulation/modeling software, thermal management application, thermal and electrical derating applications for optimized performance, critical item/supplier control, parts application, EMC/EMI, Surge suppression/Arc mitigation, sneak circuit analysis required.
• Proven understanding of DfR, Continuous Improvement/Quality tools, Robust Engineering, DOE, SPC, DFSS. Should understand DfR integration into new product development, introduction, and scaling processes. Project management experience in handling high impact/large scale projects and/or new product/process launches required.
• In-depth knowledge of power electronics and demonstrated expertise in proper application of IGBT's, drives, transformers and other active/passive components used in power conversion systems desired.
• Experience with deciphering 1-line drawings of AC/DC power distribution and air conditioning equipment required.
• Experience drawing actionable conclusions by obtaining the greatest amount of accurate data with the least amount of cost and time.
• Up to 40% travel may be required to both local and international destinations.
• Results oriented; Attention to details, getting job done quickly and efficiently and ability to cross check work.
• Excellent interpersonal communication, negotiation and conflict resolution and ability to communicate with high levels of management.

Essential Responsibilities:

• Reliability technical lead for new systems/product/process/component design, development and technology optimization of PV power plant electrical systems.
• Conduct reliability predictions, allocation and apportionment of goals, reliability/ maintainability/ availability analysis, throughput calculation, resource allocations, life cycle cost analysis using Reliability Block Diagrams (RBD) of PV power plants by accurately building reliability models from 1-line and other diagrams working closely with relevant teams.
• Work closely with systems development, engineering, and other technical teams to model systems reliability by integrating functional and reliability specifications to evaluate feasibility, alternate design approaches, changes, and customer requirements.
• Utilize parts Count and Parts stress analysis to assist in component/material specification/selection and design guard banding preceding technology/ product development.
• Establish product performance requirements criteria at design stage through PRD, Reliability Block Diagram modeling, Design/Process FMECA, process flow analysis, Fault Tree Analysis (FTA), etc.
• Ensure proper application of reliability disciplines of thermal management, mechanical and electrical derating policies for optimal operation while minimizing cost, timing, and reliability impacts.
• Assist qualification engineers to write detailed product, system and sub-system quality and reliability qualification plans to support execution of product and systems related to utility scale PV plants. Work with Qualifications, Engineering, Commissioning and O&M teams to develop DV/PV plans, Factory witness tests, site inspection checklists, receiving checklists, maintenance plans, etc.
• Responsible for implementing and maintaining a reliability database of test/failure data for components and knowledge management system of lessons learned through simulation to aid easy retrieval for analysis/reporting.
• Responsible for establishing standard metrics, standardize statistical data analysis, performance metrics, automated summary reports, feedback procedures and automate generation of outputs/reports.
• Work closely with Operation and Maintenance, Quality, Construction, Commissioning, and EPC Engineering teams to continuously monitor and address field quality and reliability issues.
• Analyze and integrate power conversion system field performance and operating history data to identify potential performance and reliability improvements using RBD techniques. Conduct what if scenario evaluations for feedback into relevant teams. Formulate lessons learned and mitigation strategies in collaboration with other stakeholders such as O&M and Performance Optimization. Prepare presentation for executive management on the progress.
• Develop total cost of ownership models and assist with maintenance schedule planning, spares, and warranty planning activities.
• Conduct internal audits to ensure compliance to processes.
• Work with suppliers to help populate System RBD's for reliability allocation and availability evaluation.
• Collaborate with suppliers, test laboratories, development engineering and qualification groups to generate DOE's for service lifetime prediction of normal/marginal product and engineering evaluation of novel materials/designs to integrate into RBD models.
• Analyze data for critical part identification and control and work with suppliers/O&M to develop effective repair/mitigation strategies.
• Conduct what-if analysis to evaluate various repair and operation strategies, to understand critical paths/components.

Reporting Relationships:

• This position will report to Head- Quality and Reliability Development.

Travel:

• No travel is required.

Estimated Annual Salary Range:

• $80,000 - $110,000 Annual Salary

US Physical Requirements:

• Will sit, stand or walk short distances for up to the entire duration of a shift
• Will climb stairs on an occasional basis
• Will lift, push or pull up to 27 pounds on an occasional basis
• Required to use hands to grasp, lift, handle, carry or feel objects on a frequent basis
• 20/40 vision in each eye, with or without correction, is required
• Must be able to comply with all safety standards and procedures
• May reach above shoulder heights and below the waist on a frequent basis
• May stoop, kneel, or bend, on an occasional basis
• Ability to wear personal protective equipment is required (including but not limited to; steel toed shoes, gloves, safety glasses, hearing protection, protective jacket or apron and arm guards)

Potential candidates will meet the education and experience requirements provided on the above job description and excel in completing the listed responsibilities for this role. All candidates receiving an offer of employment must successfully complete a background check band any other tests that may be required.

Equal Opportunity Employer Statement: First Solar is an Equal Opportunity Employer that values and respects the importance of a diverse and inclusive workforce. It is the policy of the company to recruit, hire, train and promote persons in all job titles without regard to race, color, religion, sex, age, national origin, veteran status, disability, sexual orientation, or gender identity. We recognize that diversity and inclusion is a driving force in the success of our company.