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The Field Quality & Warranty Engineer is responsible for supporting warranty-related activities and ensuring the quality, reliability, and performance of A123 Systems' High Voltage Energy Storage System (ESS) products deployed throughout the United States. This role is focused on ESS container systems and serves as the primary customer quality representative for field service operations, customer warranty investigations, and third-party service provider oversight.

The successful candidate will work closely with Engineering, Manufacturing, Service, Warranty, Supplier Quality, customers, and contracted service providers to investigate field issues, identify root cause, implement corrective and preventive actions, and verify field repairs are performed safely and in accordance with A123 quality and technical requirements.

Primary Responsibilities

Warranty & Field Quality

• Lead warranty investigations for deployed ESS container systems.

• Primary contact for any warranty & quality related inquiries.

• Review field failures and determine root cause using structured problem-solving methodologies, including 8D, 5-Why, Fishbone, DFMEA, and PFMEA.

• Coordinate containment actions, corrective actions, and preventive actions with Engineering, Manufacturing, Service, Warranty, Suppliers, and customers.

• Manage Return Material Authorization (RMA) activities and field failure documentation for customer and field product returns.

• Analyze warranty trends, field quality metrics, and returned-product data to identify recurring product, process, supplier, or service-related issues.

• Prepare technical reports and communicate findings, risk assessments, countermeasures, and action plans to internal management and customers.

• Support warranty cost reduction initiatives through robust root cause analysis and permanent corrective action implementation.

Third-Party Service Oversight

• Oversee third-party service providers performing maintenance, troubleshooting, commissioning support, inspections, and repairs on 20-ft ESS containers in the field.

• Verify field repairs meet A123 quality standards, service procedures, safety requirements, and customer expectations.

• Conduct field audits of contractors, service partners, repair practices, documentation, and workmanship.

• Review service documentation, repair reports, inspection records, test data, and closeout packages for accuracy and completeness.

• Ensure compliance with high-voltage safety procedures, lockout/tagout requirements, PPE standards, and applicable site-specific work rules.

• Provide technical guidance and quality support during critical field repairs, escalations, and customer-impacting issues.

Field Technical Support

• Support commissioning, startup, field acceptance testing, and quality-related site readiness activities on ESS Container systems as required.

• Assist with troubleshooting of electrical, mechanical, controls, battery system, and container-level ESS issues.

• Interface directly with customers regarding field quality concerns, warranty status, corrective actions, and issue resolution plans.

• Support Engineering with design, process, documentation, and serviceability improvements based on field experience and lessons learned.

• Participate in failure analysis of returned components and coordinate supplier quality investigations when required.

• Clearly communicate technical information, findings, and failure analysis results to internal and external stakeholders.

Continuous Improvement

• Monitor field quality metrics, warranty performance, reliability data, and repeat-failure trends.

• Develop and support corrective and preventive action (CAPA) activities to improve product quality, field reliability, and customer satisfaction.

• Support PFMEA, control plans, lessons learned, service procedures, inspection plans, audit sheets, and quality documentation updates.

• Identify opportunities to improve product reliability, maintainability, serviceability, and first-time fix rate.

• Develop or update quality documentation, work instructions, inspection standards, and reporting templates for field service activities.

We are seeking an experienced Diagnostics & Cybersecurity Expert to interface with automotive OEMs and subject matter experts (SMEs) to define systems and software-specific requirements. Additionally, this role will support residential, commercial, and industrial projects related to communications and cybersecurity across the company's Energy Storage product portfolio.

The ideal candidate will possess deep technical expertise in communications, diagnostics and cybersecurity, along with a strong understanding of testing methodologies to assist software developers in validating feature implementations.

Collaborate with OEMs and internal teams to define systems and software requirements for automotive diagnostics and cybersecurity.

Support residential, commercial, and industrial projects within the Energy Storage sector, ensuring robust communications and cybersecurity strategies.

Ensure alignment of diagnostics strategies with industry standards and OEM-specific protocols.

Assist software developers in testing and validating diagnostics & cybersecurity features, ensuring compliance with best practices.

Conduct hands-on testing using industry-standard tools such as CANalyzer, CANoe, DBC File Editor, PDX/ODX Editor, CDD File Editor, and Diva diagnostic testing tool, as well as any other relevant software.

Support cybersecurity risk assessments for energy storage solutions, ensuring compliance with communication security protocols.

Establish secure data transmission methodologies for connected systems in both automotive and energy storage applications.

Work cross-functionally with engineering teams to optimize system architecture for scalability and cybersecurity hardening.

Ensure compliance with automotive cybersecurity standards (such as ISO/SAE 21434) and energy storage security protocols.

Stay up to date with emerging cybersecurity threats across both automotive and energy storage industries, proactively contributing to risk mitigation strategies.

Overview:

 We are seeking an accomplished Senior Platform Software Engineer with deep expertise in embedded systems to lead the development and integration of foundational software components across both automotive ECU platforms (serving multiple OEMs) and energy storage system ECUs. This role demands a high level of technical proficiency in bootloaders, MCAL, CDD, AUTOSAR BSW, and embedded cybersecurity, as well as a collaborative mindset to enable seamless coordination with application software teams in resolving complex, system-level challenges.

The ideal candidate thrives on innovation and is eager to apply their skills across diverse domains spanning automotive and energy sectors.

Key Responsibilities:

• Architect and implement secure bootloaders and robust software update frameworks
• Develop, configure, and validate MCAL and CDD drivers for a variety of microcontrollers and peripheral devices
• Integrate and optimize AUTOSAR BSW stacks, with emphasis on:
  • Diagnostics stack (including OBD)
  • Memory stack
  • CAN stack (including J1939)
  • Crypto stack
• Implement and maintain J1939 stack functionality tailored for heavy-duty automotive platforms
• Design and implement embedded cybersecurity solutions including secure boot, cryptographic services, and memory protection
• Collaborate closely with cross-functional teams to analyze, diagnose, and resolve software issues across platform and application layers
• Interface with stakeholders to support system software integration, validation, and deployment
• Lead code reviews, mentor junior engineers, and promote software quality best practices
• Ensure adherence to safety and cybersecurity standards such as ISO 26262, ISO/SAE 21434, and ASPICE

The Simulation Engineering Team at A123 is hiring a Battery FEA Engineer with the major responsibilities of conducting cell-, module-, pack- and system- level FEA structural simulation for Li-ion batteries used in electric vehicles (EVs), plug-in hybrid electric vehicles (PHEVs), hybrid electric vehicles (HEVs) and energy storage systems (EES).

• Develop/validate non-linear FEA models of Li-ion battery cells, modules, packs and systems.
• Conduct static and dynamic FEA structural simulation, including vibration, shock, crush, etc.
• Conduct thermal-mechanical simulation through integrating thermal and FEA.
• Post-process FEA structural simulation results, to determine whether internal and external requirements can be met or not and draft the technical report.
• Structural optimization of new battery cell, module, pack and system design.
• Explore the swelling mechanism through conducting FEA structural simulation and identify its role in the long-term life usage of Li-ion battery cell/module/pack.
• Support regular and NBO structural simulation activities through our global collaboration.
• Collaborate with teammates and interact with test, validation and product engineers to identify potential simulation issues, conduct root cause analysis, and provide technical proposals/solutions to resolve the engineering problems relevant to structural simulation.
• Communicate findings to internal/external customers using appropriate media in a positive and constructive manner, and establish/maintain technical communications for any open FEA structural simulation issues. 

A123 Systems, LLC in Novi, MI is hiring a Battery Simulation Engineer for Life Model/Simulation

The Simulation Engineering Team at A123 is hiring a Battery Simulation Engineer – Life Model/Simulation with major responsibilities of developing innovative and complicated semi-empirical/semi-physics life aging models for Li-ion battery systems used electric vehicles (EVs), plug-in hybrid electric vehicles (PHEVs), hybrid electric vehicles (HEVs) and energy storage systems (ESS). The battery simulation engineer is also responsible for conducting cell-, module-, and pack-level life simulation based on developed new life aging models to predict capacity fade and impedance growth over prolonged battery usage duration.

Why You Should Work Here:

• Great annual salary dependent on experience
• Multiple health benefit options to fit you and your family.
• 401k with company match
• Employer Paid Life Insurance, STD and LTD
• Automotive Supplier Discounts including GM products.
• An abundance of voluntary benefits including Dependent Care FSA, Pet Insurance, Critical Care Insurance and more!

Primary Responsibilities:

• Conduct comprehensive literature search for summarizing all possible semi-empirical/semi-physics life aging models (SOH and DCR), including calendar/cycling capacity fade and calendar/cycling impedance growth, developed and published by various researchers and engineers in the battery modeling field.
• Propose an innovative life aging model framework based on the comprehensive literature survey conducted and the new life aging model framework needs to consider all possible feasibility factors.
• Collaborate with cell team to design, optimize and finalize life aging tests for various cell chemistry and cell types regarding to life aging model development.
• Develop innovative life aging models for various cell chemistry and cell types based on new life model framework and life test data provided by our cell team.
• Validate the proposed innovative life aging models and executing life simulation based on new validated life aging models through our in-house life simulation tool.
• Support regular and NBO life simulation workload through our global collaboration (Hangzhou, China; Novi, US; Stuttgart, German).
• Collaborate with teammates and interact with test and product engineers to identify potential life model/simulation issues, conduct root cause analysis, and provide technical proposals/solutions to resolve the technical engineering problems.
• Communicate his/her findings to internal/external customers using appropriate media in a positive and constructive manner and establish/maintain technical communications for open issues listed in assigned work.  

Supporting mechanical design team in CAD and concept development of battery packs and modules

Participation in the testing of energy storage systems (low voltage, high voltage, module level, pack level...) for vehicles and stationary applications

Operation of analysis equipment

Documentation according to specified protocols

Performing elec. and mechanical support for the our laboratory with wiring harness, E/E parts and battery systems