Warranty Analysis Engineer - HVAC and Engine systems

Role: Warranty Analysis Engineer - HVAC and Engine systems
Location: Auburn Hills, MI (On SIte)

Let s create our future together at The AES Group!

About The AES Group
The AES Group is a premier technology and engineering consulting company that has been bringing businesses and talent together for over 20 years to deliver innovative solutions that have the greatest positive impact on society. AES has helped over 40 business enterprises, including Fortune 500 companies, engage their customers, empower their employees, and transform their business operations with the power of cloud, data, AI, engineering, and other emerging technologies.

Role Overview:
We are seeking a highly motivated and detail-oriented Warranty Analysis and Resolution Engineer with strong expertise in automotive systems and fundamental engineering principles. The role focuses on warranty failure analysis, root cause investigation, component disposition, and corrective action support across powertrain and vehicle subsystems. The ideal candidate will possess hands-on engineering knowledge in areas such as powertrain, transmission, driveline, exhaust systems, HVAC, and related mechanical systems.
The engineer will work closely with quality, manufacturing, service, suppliers, and product engineering teams to improve product reliability, reduce warranty costs, and enhance customer satisfaction.

Key Responsibilities:

Perform detailed warranty part analysis and failure investigations for returned field components.
Conduct root cause analysis using engineering methodologies such as 8D, Fishbone, 5 Why, FMEA, and fault tree analysis.
Analyze failed components related to:
o HVAC systems
Support disposition activities including teardown analysis, repairability assessment, scrap/rework recommendations, and containment actions.
Collaborate with design engineering, supplier quality, manufacturing, and service teams to drive corrective and preventive actions.
Interpret engineering drawings, GD&T, material specifications, tolerance stack-ups, and validation reports.
Utilize warranty databases and analytics tools to identify trends, recurring failures, and reliability concerns.
Prepare technical reports, failure summaries, and engineering recommendations for leadership and cross-functional teams.
Support supplier discussions and technical reviews for quality improvement initiatives.
Participate in continuous improvement programs focused on warranty reduction and product reliability enhancement.
Ensure compliance with automotive quality standards and processes including APQP, PPAP, DFMEA, and PFMEA.

Mandatory skills:
Bachelor s degree in Mechanical Engineering, Automotive Engineering, or related engineering discipline.
5 10 years of experience in automotive warranty analysis, product engineering, quality engineering, or failure analysis.
Strong understanding of automotive mechanical systems and fundamental engineering concepts.
Experience with teardown analysis and component diagnostics.
Knowledge of automotive manufacturing processes, materials, and reliability engineering.
Ability to read and interpret CAD drawings, engineering specifications, and test reports.
Strong analytical and problem-solving capabilities.
Excellent communication and technical documentation skills.
Proficiency in Microsoft Office tools and engineering data analysis platforms.

Optional skills:
Experience working with OEMs or Tier-1 automotive suppliers.
Familiarity with vehicle diagnostics and field data analysis.
Exposure to warranty systems and quality management tools.
Knowledge of Six Sigma, Lean Manufacturing, or statistical analysis methods.
Understanding of hybrid/electric powertrain systems is an added advantage.