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Systems Development Application Engineer - Thermal Management Module

Job Title
Systems Development Application Engineer - Thermal Management Module
Job ID
Novi,  MI 48377
Other Location

Systems Development Application Engineer - Thermal Management Module

Novi, MI (100% On-Site)

$110,000/yr. - $135,000/yr. + Bonus – Full-time Senior Level

Our History:
From our start in 2009, Conexess has established itself in 3 markets, employing nearly 200+ individuals nation-wide. Operating in over 15 states, our client base ranges from Fortune 500/1000 companies, to mid-small range companies. For the majority of the mid-small range companies, we are exclusively used due to our outstanding staffing track record

Who We Are:
Conexess is a full-service staffing firm offering contract, contract-to hire, and direct placements. We have a wide range of recruiting capabilities extending from help desk technicians to CIOs. We are also capable of offering project based work.

The selected candidate will lead the development of Thermal Management Module (TMM) and Refrigerant Control Module (RCM) Assemblies sub-system for heat pump and dual loop systems for cabin comfort applications meeting all customer specifications and program deliverables.

Primary Responsibilities:
  • Understand customer assembly and component specifications and assure compliance of designs
  • Understand engineering statements of work (ESOWS)
  • Conduct Refrigerant Charge determination testing
  • Conduct Oil Charge determination testing
  • Conduct System verification testing (performance & oil in circulation)
  • Conduct System oil migration testing
  • Conduct Coolant distribution testing (function, performance, pressure drop, etc).
  • Troubleshoot/root cause determination of Module system related issues
  • Provide feedback to engineering for sizing, performance, oil & refrigerant trapping or slugging issues
  • Assess test results and apply design and/or prototype quality countermeasures as necessary
  • Write test reports; Summarize and formally present test results internally and externally
  • Plan and support the development of new test equipment
  • Submit test requests to labs; Direct test and lab technicians / personnel / manage outsourced tests when applicable
  • Apply APQP to the application (i.e DFMEA, SCIF, DFM/A, DVP&R, proto Control Plan)
  • Support TMM/RCM prototype and production Bill of Materials with refrigerant & oil charge amounts
  • Lead system validation test planning – DVP test plan, prototype request, and timing plan
  • Support Design and Release (D&R) process, including Design Validation & Prevalidation test plan & reports
  • Support prototype TMM/RCM planning for testing and customer deliveries
  • Support preparation of TMM/RCMs for outbound shipments/deliveries
  • Manage timing plans to support program deliverables
  • Interface with customers (internal and external)
  • Manage internal budget for TMM/RCM development and testing
  • Provide direction to CAD, CAE/CFD
  • Lead and organize validation testing per DV plan; provide PV plan oversight
  • Create and/or update core engineering standards, test procedures. and support DFMEA and regulatory requirement tools
  • Execute and document all required product development deliverables in HPDS and/or GPEP
  • Write Lessons Learned and best practices based on development experiences
  • Support development of design standards
  • Interface with multiple product group PD, Advanced Systems, Lab/Test Ops and Program Management
  • CAE
  • Manage CAE simulations of TMM/RCM system performance using HPLM request systems.
  • Ensure CAE reports are summarized and uploaded to eProj
  • Compare CAE simulations with actual test data
  • Collect supporting test data to improve simulation accuracy

Years of Experience:
  • +5 years of related experience in heat exchanger or refrigerant systems development required

  • Bachelor of Science in Mechanical Engineering required; Master’s degree preferred

Desired Competencies, Experience, & Qualifications:
  • Demonstrated ability to design, develop, test, and launch complex assemblies
  • Understanding of heat transfer, fluids, materials, controls, instrumentation, structural and NVH principles
  • Experience integrating heat exchangers, fluid lines, compressors and controls as refrigerant systems
  • Experience in interpreting customer electrical hardware and software specifications
  • Experience in quality disciplines such as DFMEA, SCIFS, etc
  • Able to interpret CFD and CAE/FEA results and utilize to optimize system design
  • Demonstrated problem-solving skills
  • Experience in project planning and management
  • Ability to conduct Technical Design Reviews
  • Proven proficiency in Microsoft Word, Excel, PowerPoint
  • Close work with the lab on system test set-up, execution, and reports


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