Final Verification Testing Engineer

About the Role

This highly technical, hands-on role requires expertise in battery technology, validation, software, databases, and automation controls. The Final Verification Testing Engineer will collaborate closely with Hardware & Software engineering teams to understand battery operations, design and build testing equipment, and ensure robust end-of-line (EOL) manufacturing and validation for electric and hybrid vehicle batteries.

Responsibilities

• Develop and implement EOL test specifications for Lithium-ion battery systems in collaboration with Systems, Electronics, and Software Engineering teams.
• Create and execute EOL Test scripts on AVL Lynx to validate battery performance according to specifications.
• Utilize battery pack cyclers and demonstrate proficiency in Direct Current (DC) and Alternating Current (AC) power flow.
• Ensure EOL test specifications meet production requirements and takt time.
• Develop process profiles for all manufacturing stations in the Manufacturing Execution System (MES), ensuring data recording and process adherence.
• Create work instructions for battery pack assembly, EOL stations, and post-EOL verification.
• Collaborate on Process Failure Mode and Effects Analysis (PFMEA) with manufacturing, systems, and quality teams.
• Troubleshoot and debug issues using CANalyzer and OEM software.
• Apply knowledge of 3-phase systems, complex power flow, energy conversion via switch-mode power electronic circuits (DC/DC converters, DC/AC converters), and electromechanical energy conversion.
• Work with Allen-Bradley PLC-5, SLC 500, ControlLogix 5000 (using RSLogix 5, 500, 5000), SoftLogix 5800, 1734-Point I/O, and RSLogix Emulate 500 software.
• Write and debug Programmable Logic Controller (PLC) ladder logic and develop Human Machine Interfaces (HMI) using FactoryTalk View Studio.
• Design, code, and maintain software applications using Object-Oriented Programming languages (C++/Java), emphasizing organized, modular, and documented code.
• Automate manufacturing operations, including communication with MS SQL servers, process traceability, control of test equipment via RS232, and data processing from OPC servers.
• Design EOL test flows for high-voltage batteries while prioritizing operator safety.
• Audit supplier test software and equipment to enhance software robustness and integrity of EOL systems in production.
• Adhere to federal, state, and company regulations, policies, and procedures.
• Perform additional duties as assigned, with predictable and reliable attendance.

Requirements

• Bachelor’s degree in Electrical, Mechanical, Computer, or Systems Engineering, or a related technical field.
• Minimum of five (5) years of experience in battery testing and validation.
• Proficiency in centralized and distributed servers, open-source code/libraries, and Controller Area Network (CAN) communication.
• Knowledge of 3-phase systems, complex power flow, energy conversion via switch-mode power electronic circuits (DC/DC converters, DC/AC converters), and electromechanical energy conversion principles for DC Machines, Synchronous Machines, and Induction Machines.
• Strong communication skills to present technical test data to internal/external customers and cross-functional teams.
• Ability to lead multiple programs and perform data processing/statistical analysis, particularly with lithium-ion test data.
• Experience handling low- and high-voltage lithium-ion battery systems, including safety standards for maneuvering large battery packs.
• Familiarity with lithium-ion cell, module, and battery pack test certifications.
• Proficiency in Microsoft Office products (Excel, PowerPoint, Outlook, OneNote, Project).
• Self-motivated problem solver with attention to detail, a drive for continuous improvement, and the ability to challenge the status quo.

Key Competencies

• Decision Making & Analysis: Makes data-driven decisions using expertise, experience, and judgment; identifies root causes and seeks input from others.
• Continual Improvement: Focuses on producing high-quality, sustainable products and processes while seeking incremental improvements.
• Takes Initiative: Drives results with urgency, persists despite obstacles, and ensures issues are resolved.
• Delivers Results: Goal-oriented with a sense of urgency to meet or exceed deadlines.
• Assertiveness: Stands by well-founded positions without unnecessary aggression or fear of disapproval.
• Mission & Values Focused: Actively supports the organization’s mission, vision, values, and strategic priorities.

Physical Requirements & Working Conditions

• Constant computer use and ability to adjust focus for prolonged screen work.
• Ability to lift and carry up to 30 pounds and position the body to reach items at various heights.
• Occasional movement in industrial environments, on uneven terrain, and in confined spaces.
• Exposure to temperature-controlled offices, outdoor weather conditions, and industrial environments with moderate noise levels.
• Visual acuity to read prints, operate instruments, and inspect machinery.
• Prolonged periods of standing, walking, bending, stretching, and repetitive actions.
• Good hand/eye coordination, single-task focus, and situational awareness.
• Ability to respond quickly to sounds and wear personal protective gear for extended periods.
• May require a rotating shift schedule, overtime, travel to various sites, and calibration/modification of equipment.

Benefits

• Paid time off: 3 weeks vacation, up to 72 hours sick leave, 15 holidays, and parental leave.
• 100% company-paid medical, dental, vision, short-term disability, long-term disability, and life insurance.
• Flexible Spending Account (FSA) and Health Savings Account (HSA) options.
• Company-provided 401K savings plan with immediately vested matching contributions.
• Voluntary benefits offerings, tuition assistance, and an Employee Referral Program.
• Employee development and career growth opportunities.

About Us

American Battery Solutions Inc. (“ABS”) manufactures advanced batteries for commercial, fleet, and industrial on- and off-road vehicles. Headquartered in Lake Orion, Michigan, with additional facilities in Ohio, ABS was acquired by Komatsu in 2023 to support Komatsu’s 2050 carbon neutrality goal. ABS operates as an independent entity, serving Komatsu applications while expanding its core commercial, fleet, and industrial business. The company boasts a world-class team of engineers with deep expertise in high-voltage, automotive-grade battery systems, from concept development and prototyping to testing, validation, and high-volume production.

Location

The ABS Headquarters and Innovation Center is located in Orion Township, Southeast Michigan—a Pure Michigan Trail Town with over 50 miles of trails, including the Polly Ann Trail, Paint Creek Trail, and Iron Belle Trail. The region offers diverse recreational opportunities, top-tier dining, educational institutions, and proximity to major sporting events.