A123 Systems LLC

DFMEA Expert

4 months ago
# of Openings
Research and Development




The Failure Mode Expert will be responsible for developing and understanding a knowledge base of lithium-ion failure modes, and applying these toward the design of lithium-ion cells. This person will be responsible for developing the primary Design Failure Mode and Effects Analysis (DFMEA) document used for all of A123’s lithium-ion cells. This entails including new failure modes as necessary, updating linkages, severities, and other aspects of the document depending on the specific cell involved. Additionally, this person will be heavily involved in root cause analyses from field failures, seeking to identify new root causes and to apply the DFMEA as necessary to solve them.


This position will interface frequently with peers responsible for cell chemistry design, cell mechanical design, requirements, validation, process design, manufacturing, and many other functions. The preferred candidate will have a track record of product development, an understanding of Tier-1 automotive, the battery industry, and demonstrated experience with failure mode analysis.


Travel up to 25% (including international) required.


This position will report to Manager, Cell Mechanical Design.


  • MS in mechanical engineering, chemical engineering, materials science, or related field of study.
  • Experience in battery industry preferred
  • Experience working in the automotive industry preferred (Tier-1 supplier particularly)
  • 3+ years in a product development role
  • Demonstrated record of launching products successfully.
  • Experience with formal root cause analysis or design of experiments (DOE) tools required (Ishikawa, Six Sigma, or other)
  • Experience with concept, design, and product validation (CV, DV, and PV) as part of a product development environment
  • Familiarity with Advanced Product Quality Planning (APQP) or similar product development process preferred
  • Understanding of Failure Mode Effects Analysis (FMEA, DFMEA, PFMEA) required
  • Excellent oral and written communication skills.


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