Global Sr. Product Reliability Manager

Global Sr. Product Reliability Manager

US-CA-Santa Rosa

Job :
Type:
Employee
# of Openings: 1
Category:
Marketing and Product Management
US-CA-Santa Rosa-1421

The Global Sr Product Reliability Manager is responsible for leading the product quality strategy across the entire lifecycle of electrical power delivery components used in Electric Submersible Pump systems. This includes downhole connectors, motor lead extensions (MLEs), penetrators, cable splices, surface connectors, and high voltage terminations. The role integrates quality expectations from Product Engineering, Manufacturing, Field Services, Supply Chain, and Sales to ensure the reliability, safety, and durability of ESP electrical components under extreme downhole conditions such as high temperature, high pressure, corrosive fluids, gas content, and vibration.

This position is critical in preventing downhole electrical failures — one of the most costly events in ESP operations.

• Engineering & Design Quality
  • Partner with Engineering to define CTQs for connectors based on ESP operating conditions (HPHT, corrosive fluids, brine, HS/CO environments).
  • Lead DFMEA, PFMEA, and design risk reviews specifically for electrical insulation systems, sealing designs, and material compatibility.
  • Oversee validation and qualification testing including:
    • High voltage dielectric testing
    • Pressure/temperature cycling
    • Thermal aging
    • Vibration and shock testing
    • Chemical compatibility (oil, brine, gas)
    • Gas diffusion testing
  • Approve engineering changes and ensure field lessons learned are fed back into design improvements.
  • Verify compliance with API 11S5, IEC, IEEE, NACE, and customer-specific ESP connector requirements.
• Manufacturing Quality
  • Ensure production quality for downhole electrical connectors, including insulation molding, epoxy systems, elastomers, seals, Orings, metallic housings, and conductor welding/termination processes.
  • Develop and maintain inspection criteria and control plans for critical features such as:
  • Insulation thickness
  • Conductor continuity and resistance
  • Crimp/weld integrity
  • Pressure barriers and sealing surfaces
  • Material traceability (metals, polymers, elastomers)
  • Lead root cause analysis for NCRs using 8D, 5‑Why, and similar methodologies.
  • Audit and qualify suppliers of high‑specification materials (e.g., polymers, epoxy systems, alloys used in sour service).
  • Ensure all manufacturing documentation (QA/QC, traveler records, certifications) adheres to industry and customer standards.
• Field Installation, Commissioning & Operational Quality
  • Analyze field failure modes including:
  • Electrical shorts
  • Insulation breakdown
  • Gas ingress
  • Connector burnouts
  • Mechanical damage during installation
  • Failure due to pressure imbalance
  • Conduct lead failure analysis reviews with Engineering and Field Services to identify root causes and prevent recurrence.
  • Develop installation quality guides for technicians performing connector assembly, potting, splicing, and surface termination work.
  • Drive improvements in installation practices to reduce handling damage and contamination.
  • Maintain feedback loops based on run‑life data, pull reports, and downhole failure diagnostics.
• Sales, Customer Interface & Commercial Quality
  • Serve as the quality technical expert for key ESP operators, service companies, and engineering customers.
  • Support Sales with technical bid packages, product reliability data, and qualification test summaries.
  • Interpret customer specifications and ensure compliance in design, testing, and manufacturing.
  • Participate in customer audits, FATs, and quality witness points.
  • Lead customer complaint investigations with detailed, transparent reporting.
• Quality Systems & Continuous Improvement
  • Own the ESP connector quality KPIs including field failure rate, early‑life failure metrics, FPY, rework, scrap, warranty cost, and root cause distributions.
  • Ensure processes comply with ISO 9001, API Q1/Q2, and customer quality systems.
  • Drive Lean, Six Sigma, and reliability improvement projects focused on failure reduction.
  • Foster a strong culture of reliability, safety, and product integrity across teams.

• Bachelor's degree in Electrical, Mechanical, Materials Engineering,…