---
title: 'Sr. Systems Reliability Engineer at Zone 5 Technologies'
canonical: 'https://feeny.ai/job/sr-systems-reliability-engineer-zone-5-technologies-united-states-a2p3hdrjt6zt'
type: 'job'
last_seen: '2026-10-27'
---

# Sr. Systems Reliability Engineer at Zone 5 Technologies

- **Company:** Zone 5 Technologies
- **Location:** United States
- **Compensation:** $148k–$219k
- **Work type:** remote
- **Posted:** 2026-10-23
- **Last confirmed live:** 2026-10-27
- **Apply:** https://job-boards.greenhouse.io/zone5technologies/jobs/5461857008

## Job description

At Zone 5 Technologies, we're redefining what's possible in unmanned aircraft systems. Our team of engineers and innovators is developing cutting-edge autonomous solutions that push the boundaries of UAS technology - solving complex challenges that matter.

We're building the future of UAS capabilities, and we're looking for exceptional talent to join us. If you're driven by hard problems, energized by rapid innovation, and ready to make an impact on next-generation flight systems, you belong here.

We are seeking a Senior Systems Reliability Engineer to lead Reliability & Maintainability (R&M) activities across the product lifecycle. This role focuses on R&M architecture, data-driven analysis, comprehensive documentation, and test planning for reliability verification. You will engage directly with customer counterparts on R&M reviews and milestone events, including Reliability Scoring Conferences, Corrective Action Boards, and Milestone B/C Design Reviews.

Key Responsibilities:

Reliability & Maintainability Architecture

- Develop and maintain the R&M Program Plan and reliability architecture documentation, including the RAM-C (Reliability, Availability, Maintainability-Cost) Rationale Report
- Lead Failure Modes, Effects, and Criticality Analysis (FMEA/FMECA), Fault Tree Analysis (FTA), and Reliability Block Diagram (RBD) development across system architecture
- Develop R&M allocations and apportion reliability and maintainability requirements to lower-level items; support R&M requirements analysis and trade studies
- Draft Reliability Predictions (per MIL-HDBK-217 and related methods) and Maintainability Analyses; maintain traceability between R&M requirements, predictions, and demonstrated performance
- Lead Reliability-Centered Maintenance (RCM) and Level of Repair Analysis (LORA); support Testability and Built-In Test (BIT) analysis

Data, Documentation & Test Planning

- Establish and own the Failure Reporting, Analysis, and Corrective Action System (FRACAS); maintain closed-loop failure data collection and trending from design through test, production, and sustainment
- Develop Failure Definitions and Scoring Criteria (FDSC) and reliability test plans tied to program milestones
- Lead reliability growth planning and execution of reliability growth and demonstration testing, including Environmental Stress Screening (ESS) and HALT/HASS where applicable
- Support Qualification Test Plan development, all-up-round testing, and flight and live-fire test reliability assessments
- Develop technical documentation including R&M standards, specifications, procedures, and user guides
- Review ground test, flight test, and live-fire test data to confirm R&M requirements compliance

Customer Engagement & Reviews

- Serve as primary point of contact with customers on R&M matters
- Present R&M analyses, RAM-C Rationale Report updates, and risk posture at Milestone Reviews (A/B/C) and design reviews (PDR, CDR, TRR, PRR)
- Lead Reliability Scoring Conferences and Corrective Action Boards (CAB) with customer participation
- Coordinate responses to customer R&M data item deliverables and support In-Service Reviews

Risk Management & Process Improvement

- Lead Root Cause and Corrective Action (RCCA) investigations for failures identified through FRACAS
- Host corrective action reviews and ensure lessons learned are implemented across the program
- Coordinate R&M risk mitigation with Manufacturing Engineering, Logistics, Quality, and System Safety, including DMSMS/obsolescence and shelf-life and aging surveillance considerations
- Apply digital engineering and AI-enabled tools (predictive maintenance, digital twins, automated FRACAS analytics) to R&M processes
- Ensure compliance with MIL-STD-785, MIL-HDBK-217, GEIA-STD-0009, and other applicable R&M standards

Basic Qualifications:

- 7+ years as a Reliability Engineer, R&M Engineer, or equivalent reliability-critical engineering role
- Bachelor's degree in Mechanical, Aerospace, Systems, or Electrical Engineering, or Physics
- Expertise with MIL-STD-785, MIL-HDBK-217, and related R&M standards
- Experience owning FRACAS, including failure tracking, root cause analysis, and corrective action closure
- Proven experience developing and executing reliability test plans, including growth testing, demonstration testing, and Environmental Stress Screening
- Experience engaging with customers on R&M reviews and milestone/design reviews (PDR, CDR, Milestone B/C)
- Strong system architecture knowledge and R&M requirements decomposition and allocation
- Extensive FMEA/FMECA, FTA, and RBD experience
- Failure investigation with proven corrective action implementation
- Technical writing for R&M program plans, rationale reports, procedures, and documentation
- Design review experience (PDR, CDR, MRR) with strong presentation skills
- Data collection, analysis, and trending for R&M metrics
- U.S. Citizenship

Preferred Qualifications:

- Master's degree in engineering or related field
- 10+ years progressive R&M experience
- ASQ Certified Reliability Engineer (CRE) or equivalent certification
- DoD or Navy R&M programs experience, aligned with SECNAV Reliability and Maintainability Engineering guidance
- Quantitative reliability growth modeling (e.g., Crow-AMSAA) and Weibull analysis
- Maintainability, Testability/BIT, LORA, and RCM experience
- Missile, hypersonic, or munitions systems experience, including all-up-round reliability, environmental stress screening, and shelf-life/stockpile surveillance programs
- Digital engineering and AI-enabled R&M tools (predictive maintenance, digital twins, automated FRACAS analytics)
- Active U.S. Security Clearance or ability to obtain

Level IV - $148k - $180k Level V - $180k - $219k Pay range for this role $148,000—$219,000 USD

What's in it for you:

Benefits:

- Competitive total compensation package
- Comprehensive benefit package options include medical, dental, vision, life, and more.
- 401k with company-match
- 3 weeks of paid time off each year
- 40 hours of sick time
- 12 annual company holidays

Why Join Zone 5 Technologies?

- Innovative Environment: Work on cutting-edge technology that is shaping the future of defense and aerospace.
- Collaborative Culture: Join a team of passionate professionals dedicated to pushing the boundaries of what’s possible.
- Career Growth: Opportunities for professional development and career advancement.

If you are passionate about unmanned aircraft technology and want to be a part of a dynamic and growing company, we would love to hear from you. Apply today and join the Zone 5 Technologies team!

In compliance with federal law, all persons hired will be required to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form upon hire.

Zone 5 Technologies is a federal contractor and participates in E-Verify to confirm employment eligibility. As required by law, we will verify the identity and employment authorization of all new employees using the E-Verify system. Learn more about your rights and responsibilities under E-Verify: https://www.e-verify.gov.

## About Zone 5 Technologies

## Company Overview
- **One-liner**: Zone 5 Technologies develops advanced unmanned aircraft systems (UAS) and next-generation munitions for U.S. Department of Defense customers, with a focus on modular, open-architecture designs and rapid prototyping.
- **Entity Type**: Private (acquired by Kongsberg Defence & Aerospace; prior to acquisition was privately held)
- **Headquarters**: San Luis Obispo, California, United States
- **Founded**: 2011
- **Founders**: Not publicly available

## Core Business
- **Primary Industry**: Aviation and Aerospace Component Manufacturing; Defense Technology
- **Target Customers**: U.S. Department of Defense (DoD), Defense Innovation Unit (DIU), and allied military forces (B2G)
- **Mission Statement**: "Create the future" – focused on enabling modularity, collaboration, and rapid deployment of unmanned systems and munitions.

## Products & Services
- **Paladin UAS**: A multi-mission, TAK-integrated unmanned aircraft system that serves as an autonomous wingman. Capabilities include counter-UAS interception, precision munitions drop, and rifle takedowns. Listed on the DIU Blue UAS Refresh list, ensuring NDAA compliance and cybersecurity. (Hardware + Software)
- **White Spike Interceptor**: A modular, open-C2 missile and launcher system available in surface‑ and air‑launched configurations. Designed for counter-UAS and precision strike missions. (Hardware + Software)
- **Air Launched Effects (ALE)**: Low‑cost, digitally engineered effects for affordable mass and precision strike from mobility, bomber, and tactical aircraft. (Hardware + Software)
- **Next‑Gen Munitions**: Low‑cost containerized missile systems, including the Extended Range Attack Munition. (Hardware)
- **Engineering Services / R&D**: End‑to‑end system development including CONOPS, vehicle design, avionics, embedded hardware/software, ground control stations, and mission planning software.

## Market Standing
- **Valuation/Market Cap**: Not publicly disclosed (acquired by Kongsberg Defence & Aerospace)
- **Key Metric**: Total headcount of 183 (LinkedIn, 2026‑07), representing +241.1% year‑over‑year growth
- **Notable Investors/Partners**: Kongsberg Defence & Aerospace (acquirer); DIU (multiple contract awards); U.S. Air Force
- **Growth Signals**:
  - 241% headcount growth in the last year
  - Selected for multiple DoD/DIU programs: Blue UAS Refresh, Low‑Cost Containerized Missiles, Counter UAS Next, Extended Range Attack Munition, Enterprise Test Vehicle
  - 108 active job postings (260% year‑over‑year increase)
  - 13,284 LinkedIn followers (+62% yearly)

## Competitive Advantages
- **Vertical Integration**: Concept‑to‑production capability – design, manufacturing, testing, and sustainment in‑house.
- **Open Systems / Modularity**: MOSA/WOSA architectures enable rapid adaptation of vehicles, sensors, and weapons.
- **Blue UAS Listing**: Provides an Authority to Operate (ATO) for all DoD operators, a key differentiator for government contracts.
- **Flight‑Proven Hardware**: Paladin and White Spike have undergone extensive flight testing (SIL, HIL, flight tests).
- **Agile Prototyping**: Low‑cost, digitally engineered designs allow for fast iteration and unit‑cost discipline.

## Strategic Focus
- **Expanding DoD & Allied Contracts**: Leveraging recent DIU and Air Force wins to secure production orders for Paladin, White Spike, and missile systems.
- **Scaling Workforce & Capabilities**: Rapid hiring across engineering (GNC, embedded, avionics, flight test) to support increasing program loads.
- **International Expansion**: Acquisition by Kongsberg may open access to NATO and allied markets.
- **Next‑Gen Munitions**: Emphasis on affordable mass – developing low‑cost missiles for high‑volume procurement.

## Why Work Here
- **Culture & Ratings**: Employer rating 4.2/5 on LinkedIn (based on 8 reviews); Work‑Life 4.0, Compensation 3.6, Culture 3.4, Career 3.8.
- **Growth Opportunity**: 108 open positions across software, hardware, flight test, and manufacturing – strong upward mobility in a rapidly expanding company.
- **Technical Environment**: Tech stack includes Python, MATLAB, C++, CUDA, PyTorch, Docker, Kubernetes, PostgreSQL, React, GitLab, Jenkins, and more – modern engineering tools.
- **Mission‑Driven Work**: Directly contribute to defense technology that is fielded today (Blue UAS, interceptor programs).
- **Location**: San Luis Obispo, CA – a vibrant college town near the Central Coast with outdoor lifestyle.
- **Hybrid/Remote**: Not specifically stated; most roles appear on‑site at one of three U.S. offices (San Luis Obispo, Fort Walton Beach FL, Fort Worth TX).

## Sources
1. [LinkedIn – Zone 5 Technologies](https://www.linkedin.com/company/zone-5-technologies)
2. [Company Website – zone5tech.com](https://www.zone5tech.com/)
3. [Greenhouse Careers Page](http://job-boards.greenhouse.io/zone5technologies)
4. [robotics.press – Company Profile](https://robotics.press/news/zone-5-technologies-company-profile/)
5. [YouTube – Zone 5 Technologies](https://www.youtube.com/@Zone5Technologies)

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