Battery Pack Test Engineer

Ford • Dearborn, MI

1d • $86,600 - $166,200 • Hybrid

About The Position

We are seeking a Battery Pack Test Engineer with strong expertise in battery manufacturing test systems and National Instruments software platforms, specifically LabVIEW and NI TestStand. This role will be responsible for improving battery pack test processes and developing standardized software solutions for battery testing applications, including end of line cycler testing, high-voltage electrical testing, and leak testing. The candidate will also lead the development of a VI software library for battery testing to support common test functions, standardization, scalability, and reuse across manufacturing and
Key Responsibilities:

Process Improvement and Collaboration
Improve battery pack test processes to enhance safety, quality, productivity, and manufacturability.
Investigate, evaluate, and implement new technologies for battery cell, array, and pack testing.
Develop and standardize software for battery pack end-of-line electrical testers.
Develop and standardize software for battery pack leak testers.
Develop software applications for battery test systems using NI LabVIEW and NI TestStand.
Support development of software for battery testing applications, including cycler testing, high-voltage testing, insulation resistance, OCV, charge/discharge, and related electrical test processes.
Build, maintain, and expand a VI software library for battery testing to enable common architecture, code reuse, and standardized test development.
Develop, validate, and deploy reusable test sequences, drivers, interfaces, and reporting tools for battery test equipment.
Support integration of software with test hardware, instrumentation, PLCs, DAQ systems, cyclers, and high-voltage test equipment.
Implement standardized engineered solutions for manufacturing test equipment, prioritizing ergonomics, safety, productivity, and process conformity.
Drive investment efficiency processes with Product Development (PD) and Joint Venture (JV) partners.
Incorporate continuous improvements using ME Continuous Improvement, Lessons Learned, Deviation, and Decision Record processes.
Participate in peer reviews and share lessons learned across the organization.
Collaborate with cross-functional teams to optimize production and test processes and improve product quality.
Monitor and analyze production and test data to identify areas for improvement and implement corrective actions.
Safety and Compliance
Ensure compliance with Ford safety regulations and industry standards for battery manufacturing and high-voltage test systems.
Support safe development and implementation of battery test software and controls for high-voltage applications.
Travel to domestic and international manufacturing facilities to collaborate with team members, oversee vendor runoff, and support in-plant runoff.
Communicate effectively with team members, stakeholders, and JV partners to ensure project success and timely delivery.
Other Tasks
Lead runoff, delivery, and launch of new or re-tooled equipment supporting new programs.
Follow quality processes such as Reconciliation Matrix/Control Plan, SCCAF, PFMEA, and Error Proofing.
Champion review and approval of OEM safety risk assessments with Controls and Safety teams.
Attend and support all layout reviews.
Oversee production line operation through launch, ensuring quality and efficiency standards are met.
Manage program timelines for assigned areas and implement recovery actions as needed.
Support software troubleshooting, debugging, validation, and issue resolution during installation, commissioning, and launch.

Requirements

• Bachelor’s degree in Electrical Engineering, Computer Engineering, Controls Engineering, or related field.
• Minimum of five years of experience in Battery Test Engineering, Test Systems Engineering, or a related field.
• Strong hands-on programming experience with NI LabVIEW is required.
• Strong hands-on experience with NI TestStand is required.
• Experience developing software for battery testing systems, including cycler testing, high-voltage electrical testing, and end-of-line test applications.
• Experience building and maintaining reusable VI libraries, modular software architectures, and standardized test frameworks.
• Experience integrating software with instrumentation, DAQ hardware, PLCs, power supplies, cyclers, and high-voltage test equipment.
• Strong troubleshooting and problem-solving skills.
• Strong analytical ability and a data-driven mindset.
• Experience with computers, electronics, and test equipment applications.
• Ability to work independently and collaboratively in cross-functional teams.
• Ability to learn product function and manufacturing process requirements.
• Ability to manage multiple priorities simultaneously.
• Ability to adapt to a dynamic work environment and diverse team structure.
• Comfortable with high travel demand, both domestic and international.
• Ability to travel up to 50% outside the Midwestern region during installation, commissioning, and launch phases.

Nice To Haves

• Project management experience.
• Self-starter with a strong learning mindset, high motivation, and strong organizational, communication, and influencing skills.
• Strong leadership skills with the ability to handle technical aspects of the position.
• Knowledge of battery and array sub-component function.
• Base knowledge of various battery test processes such as Hi-Pot, IR, OCV, charge/discharge, cycler testing, and leak testing.
• Mechanical and Controls Engineering aptitude.
• Machine design knowledge or experience.
• Familiarity with statistical software such as Minitab.
• Experience leading technical activities across remote sites.
• Experience with software validation, requirements definition, version control, and test system standardization.
• Experience supporting manufacturing launch and production test system commissioning.

Responsibilities

• Improve battery pack test processes to enhance safety, quality, productivity, and manufacturability.
• Investigate, evaluate, and implement new technologies for battery cell, array, and pack testing.
• Develop and standardize software for battery pack end-of-line electrical testers.
• Develop and standardize software for battery pack leak testers.
• Develop software applications for battery test systems using NI LabVIEW and NI TestStand.
• Support development of software for battery testing applications, including cycler testing, high-voltage testing, insulation resistance, OCV, charge/discharge, and related electrical test processes.
• Build, maintain, and expand a VI software library for battery testing to enable common architecture, code reuse, and standardized test development.
• Develop, validate, and deploy reusable test sequences, drivers, interfaces, and reporting tools for battery test equipment.
• Support integration of software with test hardware, instrumentation, PLCs, DAQ systems, cyclers, and high-voltage test equipment.
• Implement standardized engineered solutions for manufacturing test equipment, prioritizing ergonomics, safety, productivity, and process conformity.
• Drive investment efficiency processes with Product Development (PD) and Joint Venture (JV) partners.
• Incorporate continuous improvements using ME Continuous Improvement, Lessons Learned, Deviation, and Decision Record processes.
• Participate in peer reviews and share lessons learned across the organization.
• Collaborate with cross-functional teams to optimize production and test processes and improve product quality.
• Monitor and analyze production and test data to identify areas for improvement and implement corrective actions.
• Ensure compliance with Ford safety regulations and industry standards for battery manufacturing and high-voltage test systems.
• Support safe development and implementation of battery test software and controls for high-voltage applications.
• Travel to domestic and international manufacturing facilities to collaborate with team members, oversee vendor runoff, and support in-plant runoff.
• Communicate effectively with team members, stakeholders, and JV partners to ensure project success and timely delivery.
• Lead runoff, delivery, and launch of new or re-tooled equipment supporting new programs.
• Follow quality processes such as Reconciliation Matrix/Control Plan, SCCAF, PFMEA, and Error Proofing.
• Champion review and approval of OEM safety risk assessments with Controls and Safety teams.
• Attend and support all layout reviews.
• Oversee production line operation through launch, ensuring quality and efficiency standards are met.
• Manage program timelines for assigned areas and implement recovery actions as needed.
• Support software troubleshooting, debugging, validation, and issue resolution during installation, commissioning, and launch.

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