Sr. Service Lab Technician BESS, Ford Energy
The Senior Service Lab Technician, Battery Energy Storage Systems (BESS) plays a critical role in diagnosing, testing, and developing service procedures for Ford Energy’s Battery Storage System. You will simulate environmental/fault conditions, perform complex electrical diagnostics, and validate repair methodologies. As a senior member of the lab team, you will act as a champion for high-voltage safety compliance, mentor junior technicians, and actively contribute to root-cause analysis (RCA) to improve product reliability. Responsibilities Key Responsibilities Documentation & Technical Writing Contribute to and help optimize Ford's technology roadmap by providing hands-on lab testing insights, data, and technical feedback that inform product development timelines and priorities. Author, review, and validate step-by-step Standard Operating Procedures (SOPs), safety guides, and Technical Service Bulletins (TSBs) for field technicians. Document and compile test logs, teardown results, and failure investigation data into clear, concise technical reports for design and quality engineering teams. Support the development of standardized cost structures for authorized third-party service providers by delivering accurate lab testing data, benchmarks, and technical assessments. Diagnostics, Troubleshooting & Root Cause Analysis Perform high-level diagnostics and fault isolation on field-returned BESS components, including battery management systems (BMS), high-voltage junction boxes, power distribution units, and thermal management (HVAC/liquid cooling) systems. Utilize advanced diagnostic software, CAN bus analysis tools (e.g., Vector CANalyzer), oscilloscopes, and thermal imaging cameras to identify hardware, software, and communication failures. Testing & Validation Operations Set up and operate battery test equipment, battery pack cyclers, hardware-in-the-loop test rigs, and data acquisition systems. Execute complex electrical, thermal, and mechanical test plans to validate proposed service parts, firmware/software updates, and field repair procedures. Fabricate and assemble custom test fixtures, wire harnesses, and prototype components to support special engineering investigations. Environmental, Health and Safety & Lab Stewardship Enforce and adhere to the highest standards of lab safety, including NFPA 70E, OSHA regulations, and corporate high-voltage (HV) safety policies. Act as an authorized person for Lock Out / Tag Out (LOTO) procedures on live HV DC and AC systems. Maintain, calibrate, and organize laboratory equipment, hand tools, specialized diagnostics, and high-voltage Personal Protective Equipment (PPE). Assess and implement ergonomic best practices in field settings, adapting tools, equipment, and work postures to reduce physical strain and injury risk across variable, non-lab environments. Team Leadership & Collaboration Train and mentor field technicians on safety protocols, testing techniques, and equipment operations. Collaborate closely with BESS Design, Software, Quality, and Field Engineering teams to provide actionable feedback on product serviceability and reliability. Qualifications Position Qualifications and Key Capabilities Education: Associate degree in Electrical Engineering Technology, Electronics, Mechanical Technology, or equivalent military training/trade school certification. Experience: 5+ years of hands-on experience in a development lab, quality lab, or manufacturing repair environment working directly with high-voltage (HV) electrical systems or battery systems (BESS, EV battery packs, power electronics). Technical Skills: Strong working knowledge of DC electricity (up to 1500V or higher) and three-phase AC power systems. High proficiency reading and interpreting complex electrical schematics, single-line diagrams, piping and instrumentation diagrams, and technical drawings. Experience with automotive/industrial network communication protocols (CAN, Modbus, TCP/IP, Ethernet). Hands-on proficiency with diagnostic equipment: digital multimeters (DMMs), insulation resistance testers (Megger), high-voltage probes, and thermal cameras. Certifications: Active or prior certification in high-voltage safety (e.g., NFPA 70E, OSHA 10 or 30). Preferred BESS experience EV battery Experience operating battery cyclers and programming automated test sequences. Demonstrated experience with structured root-cause analysis tools. Familiarity with liquid-cooling thermal management systems, pump maintenance, or refrigeration systems. Physical Demands & Working Conditions Must be comfortable working in a technical laboratory that’s an active workshop environment. Also, having to perform site visits at customer locations. Ability to safely handle high-voltage equipment, heavy machinery, and hazardous materials (with PPE). Physical ability to stand for long periods, work in confined spaces when necessary, and lift/move equipment weighing up to 50 lbs. Willingness to wear required PPE, including arc flash suits, safety glasses, steel-toed boots, and high-voltage insulated gloves. Occasional domestic or international travel (up to 20-30%) to support field validation, commissioning, or emergency high-level customer interventions. This position is based out of Ford’s Engineering Lab in Dearborn Michigan. Travel Expectations: This role requires travel to partner sites, certification labs, and customer installations (including potential international travel) to support technical testing, validation and integration activities.
Automotive/industrial network communication protocols (CAN, Modbus, TCP/IP, Ethernet)
Diagnostic equipment (DMMs, Megger, high-voltage probes, thermal cameras)
Operating battery cyclers and programming automated test sequences
Liquid-cooling thermal management systems