Battery Lab Advanced Test Engineer

Ford Motor • Allen Park, MI

2d • Hybrid

About The Position

In this position... An Electrified Powertrain Integration Center (EPIC) Battery Lab Test Engineer is responsible for leading quality initiatives which includes reducing warranty claims by way of reviewing DVM’s for completeness, making modifications to existing DVM’s, and proposing new DVM’s while also being responsible for validating the new/modified test and reviewing data. You primarily work hand-in-hand with D&R engineers, test engineers, OPD, CAE engineers, functional quality leads, as well as test technicians/analysts, and test equipment vendors, to support the company's testing needs for reducing warranty costs to HV batteries and their subsystems. Primary Duties: Regular/Daily tasks include: 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

Requirements

• B.S. in Engineering or related degree
• 3+ years battery lab test engineering experience required
• 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

Nice To Haves

• project management experience or master’s degree a plus
• MATLAB, Minitab, VB/Excel Macro skills a plus.
• Jira and AIMs familiarity a plus

Responsibilities

• 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

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 5,001-10,000 employees