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Ford Motor Company · 4 days ago

Battery Lab Advanced Test Engineer

Allen Park, MI

Full-time

Hybrid

Mid, Senior Level

3+ years exp

Ford Motor Company is a global leader in the automotive industry, seeking a Battery Lab Advanced Test Engineer to lead quality initiatives in their Electrified Powertrain Integration Center. The role involves developing DV plans, improving lab automation, and collaborating with various engineering teams to validate tests and reduce warranty costs for high voltage batteries.

AutomotiveAutonomous VehiclesManufacturingTransportation

No H1B

Responsibilities

Development of DV plans with efficient test timing and 100% issue/error detection (product or test execution related) with an emphasis on Full Automation / Requester Not Present

Create and improve automation in the lab by way of AVL/equipment

Support accurate and complete metrics reporting

Responsible for warranty reporting check ins with senior management

Management of test requests, schedules, and facilities; accurate daily ELMS reporting

Perform data analysis, generating comprehensive technical reports

Develop, procure, and install new test equipment systems to support current and future testing

Lead/Support the creation/publication of standardized test methods

Providing direction to Test Analysts to aid in quality improvement with the focus of warranty claim reduction

Create and translate test request requirements into lab executable instructions / test plans

Assisting technicians in the day-to-day execution of testing

Leading test site troubleshooting efforts

Providing training to incoming Test Engineers to aid in the quality improvement with the focus of warranty claim reduction

Help new TE’s understand how to test to reduce warranty claims

Guide others on adding and improving automation to test scripts

Provide ‘mentor’ style experience to assist less experienced engineers with processes/practices

Be a continual resource for test stand setup and execution questions

Implementation of standard practices for lab processes. Document said processes and provide instruction to team members on their execution

Provide guidance to VEV and requestor engineers and analysts related to development of test procedures / scripts to examine previously untested parameters and identify ways to monitor those parameters

Configuring/Operating Lynx site automation systems and supplemental site controls and I/O to achieve fully automated testing and 100% error detection/response

Creating and maintaining test parameter files, test limits, quality parameters and automation scripts

Improve setups for a higher automation capability

Troubleshoot and problem solve data upload and synchronization issues with Ford Santorin server

Conduct research based on these findings to determine future data acquisition tools, software and hardware

Analyzing test data for performance/execution issues

Develop detection strategies for issues not captured by the site control system; facilitate data delivery to customer

Review test results for quality of data, identify areas for improvement in both measurements taken and testing executed

Suggest and implement changes to tests to fully encompass projected customer use in order to mitigate warranty claims

Champion projects to expand battery testing capabilities

Developing test equipment / facility upgrade capital project proposals

Authoring specification and statement of work documents

Building financial and business rationale, obtaining cost estimates

Developing project timing plans and managing capital projects, including tracking and managing cost, timing, and equipment installations, leading activities with equipment vendors and skilled trades, and coordinating with Lab Scheduling

Support standard DCV/TPV/KLT and milestone testing

Make sure milestone developmental testing is on track

Run SCO, Thermal, Cell Integration, Functional and Robustness, and Environmental

Propose changes to milestone testing to improve automation, improve timing delivered, and/or increase test run efficiency

Conduct test safety sign-offs prior to initiation of test scripts

Understand each test setup and its requirements

Stay current on changing methodologies through which test setups are verified through engagement with appropriate battery Subject Matter Experts (SMEs)

Utilize test signoff checklist to verify test setups are complete and all safety protocols have been implemented appropriately prior to test start

If errors or omissions in test setups are found, provide training to setup personnel regarding the problems that were found and techniques through which improvements to the process can be made

Qualification

Battery lab test engineeringData analysisHigh Voltage systemsAutomation skillsInstrumentation measurement systemsProject managementAnalytical skillsMS OfficeMATLABMinitabVB/Excel MacrosJira familiarityAIMs familiarityTeamworkOral communicationWritten communication

Required

B.S. in Engineering or related degree

3+ years battery lab test engineering experience required; project management experience or master's degree a plus

An understanding of vehicle powertrain, power supply, and vehicle electrical system operation and interaction with an emphasis on High Voltage / HEV / BEV applications

A thorough knowledge of data collection and communication systems and their operation, including AVL Lynx, WAGO watchdog systems, and CAN/Ethernet/Modbus Communication protocol

A thorough knowledge of instrumentation measurement systems, particularly those relating to battery testing (CAN variables, current, voltage, coolant, and ARXML)

A thorough knowledge of lab scheduling and management tools, including ELMS for test status setting and communications

Demonstrated leadership behaviors and related experience

Strong teamwork, analytical, oral, and written skills

MS Office skills required; MATLAB, Minitab, VB/Excel Macro skills a plus. Jira and AIMs familiarity a plus