Description

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.

1. 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:
• Highvoltage 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.12829170

• 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 manufac14969251turing documentation (QA/QC, traveler records, certifications) adheres to industry and customer standards.

• Analyze field failure modes including:
• Electrical shorts
• Insulation breakdown
• Gas ingress
• Connector burnouts
• Mechanical damage during installation
• Failure due to pressure imbalance
• 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.

• 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.

• Own the ESP connector quality KPIs:
• Field failure rate (per 1,000 runs)
• 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, or related field.
• 10+ years of experience in product or manufacturing quality for ESP systems, downhole electrical equipment, or oilfield tools.
• Percent of Travel: 50%+
• Strong understanding of:
• Electrical insulation systems
• High-voltage components
• Downhole sealing and pressure barriers
• Polymer and elastomer behavior under HPHT
• Hands-on experience with DFMEA, PFMEA, control plans, RCA, and reliability engineering.
• Ability to read technical drawings, connector schematics, and downhole assembly diagrams.
• Strong communication and cross-functional leadership skills.

Preferred Qualifications

• Master's degree or MBA.
• ASQ CQE, Six Sigma Black Belt, API Q1/Q2 certification.
• Experience with ESP cable systems, connectors, and penetrators (surface and downhole).
• Familiarity with testing standards such as IEEE, IEC, API 11S5, NACE MR0175/ISO 15156.

Core Competencies

• Technical depth in electrical and mechanical systems
• Reliability engineering mindset
• Root-cause analysis excellence
• Customer-focus
• Data-driven decision-making
• Strong cross-functional collaboration
• Continuous improvement leadership

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