Battery Pack Test Engineer Job at Ford Motor Company (Dearborn)

Job Description

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

Job Responsibility

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

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 have

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

What we offer

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

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Battery Pack Test Engineer

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