Position Summary
The Test Engineer is responsible for developing, supporting, and optimizing manufacturing test systems and processes for battery pack production. This role plays a critical part in ensuring product quality, reliability, safety, and production efficiency through the implementation and continuous improvement of testing equipment, methodologies, and data analysis.
The Test Engineer will work closely with Manufacturing, Quality, Product Engineering, and Operations teams to support production testing activities, troubleshoot test failures, improve test coverage, and drive process improvements. This position requires strong technical expertise in electrical and electronic systems, automated test equipment, and PCBA testing.
Key Responsibilities
Manufacturing Test Support
- Support production testing of battery packs, subassemblies, and electronic components, including end-of-line (EOL), functional, safety, and performance testing.
- Troubleshoot and resolve test failures, equipment issues, and process-related testing concerns.
- Provide hands-on support to manufacturing operations to minimize downtime and improve productivity.
- Monitor test system performance and identify opportunities to improve reliability, repeatability, and throughput.
- Support production ramp-ups, process changes, and new product introductions (NPI).
Test Equipment & Process Development
- Design, develop, validate, and maintain manufacturing test equipment, fixtures, and automated test systems.
- Develop test procedures, specifications, acceptance criteria, and work instructions.
- Improve existing test methods and implement new testing technologies to enhance quality and manufacturing efficiency.
- Support equipment qualification, calibration, preventive maintenance, and validation activities.
- Collaborate with cross-functional teams to ensure test systems meet product and manufacturing requirements.
PCBA Testing & Electronics Support
- Develop and maintain test methodologies for printed circuit board assemblies (PCBAs) used in battery packs and Battery Management Systems (BMS).
- Support functional testing, programming, validation, and troubleshooting of electronic assemblies.
- Analyze electronic failures and work with Product Engineering and Manufacturing teams to determine root causes and implement corrective actions.
- Utilize electrical test equipment such as oscilloscopes, digital multimeters, data acquisition systems, power supplies, and communication analyzers.
- Support verification of engineering changes affecting electronic hardware and firmware.
Data Analysis & Continuous Improvement
- Analyze test and manufacturing data to identify trends, recurring failures, and process improvement opportunities.
- Generate reports and dashboards to support production and quality decision-making.
- Lead root cause investigations using structured problem-solving methodologies.
- Implement corrective and preventive actions to improve product quality and test effectiveness.
- Support yield improvement initiatives and reduction of false failures and test escapes.
Quality, Documentation & Compliance
- Create and maintain test documentation, procedures, validation reports, and engineering records.
- Support quality system requirements, audits, and process validation activities.
- Participate in risk assessments, PFMEAs, and Control Plan development.
- Ensure testing processes comply with company, customer, safety, and regulatory requirements.
- Promote safe work practices when working with battery systems, electrical equipment, and manufacturing machinery.
Required Qualifications
- Bachelor's degree in Electrical Engineering, Electronics Engineering, Mechanical Engineering, Manufacturing Engineering, Mechatronics, or a related engineering discipline.
- Minimum of 3 years of experience in test engineering, manufacturing engineering, electronics testing, or a related technical field.
- Experience supporting test systems in a manufacturing environment.
- Strong troubleshooting and root cause analysis skills.
- Experience working with electrical test and measurement equipment.
- Ability to read and interpret electrical schematics, wiring diagrams, and technical documentation.
- Strong communication skills and ability to collaborate across multiple functions.
Preferred Qualifications
- Experience in battery pack manufacturing, energy storage products, automotive systems, or related industries.
- Experience with Battery Management Systems (BMS) and battery pack electronics.
- Knowledge of PCBA manufacturing and test methodologies, including functional test (FCT), in-circuit test (ICT), and board-level diagnostics.
- Experience with automated test equipment (ATE) and industrial automation systems.
- Familiarity with Manufacturing Execution Systems (MES) and production traceability systems.
- Experience using data analysis and visualization tools such as Power BI, SQL, Python, Minitab, or JMP.
- Knowledge of communication protocols including CAN, LIN, Ethernet, RS-232, and RS-485.
- UN38.3 testing
- IEC 62133 / UL certification
- Environmental and abuse testing
Technical Skills
- Battery pack testing and validation
- End-of-line (EOL) manufacturing testing
- Functional and electrical testing
- PCBA testing and troubleshooting
- Battery Management Systems (BMS)
- Automated Test Equipment (ATE)
- Electrical diagnostics and instrumentation
- Data acquisition and analysis
- Root cause analysis and corrective action implementation
- Test fixture design and development
- Manufacturing process support
- Statistical analysis and process monitoring
- Test software and hardware integration
Competencies
- Strong analytical and problem-solving skills
- Attention to detail and commitment to quality
- Data-driven decision-making
- Effective written and verbal communication
- Cross-functional teamwork and collaboration
- Organizational and project management skills
- Ability to work independently in a fast-paced manufacturing environment
- Strong sense of ownership, accountability, and urgency
- Continuous improvement mindset
Work Environment
- Fast-paced manufacturing environment focused on battery pack assembly and testing.
- Frequent interaction with automated production equipment, test systems, battery products, and electronic assemblies.
- Hands-on involvement in troubleshooting production test stations, validating test processes, and supporting manufacturing operations.
- Collaboration with Manufacturing, Quality, Operations, and Product Engineering teams to improve product quality and production performance.
- Occasional support may be required during off-shift production activities, equipment installations, product launches, and critical manufacturing events.
Physical Requirements
- Ability to stand and walk for extended periods in a manufacturing environment.
- Ability to occasionally lift and move materials or equipment up to 25 pounds.
- Ability to work safely around electrical systems, automated equipment, and battery products while following established safety procedures.
- Ability to perform hands-on troubleshooting, equipment setup, and maintenance of test equipment and fixtures.
Why Join Us
As a Test Engineer, you will play an important role in delivering high-quality battery products by developing and improving the testing systems that ensure product performance, reliability, and safety. This position offers the opportunity to work with advanced battery technologies, automated test systems, and complex electronics while contributing directly to manufacturing excellence and continuous innovation.