Sustaining Engineer

Sustaining EngineerOnsite in Foster City, CA | 5 days in office Minimal domestic travel will be requiredAt Zoox, we are developing autonomous mobility solutions that require high fleet availability to support testing, mapping, and operational readiness. The Level 3 Toyota Highlander fleet plays a critical role in these efforts, and the Sustaining Engineering team owns the reliability and availability of these vehicles in operation. As a Sustaining Engineer, you will support the L3 test fleet by resolving issues across both OEM vehicle systems and Zoox integrated AV hardware. This role requires broad ownership across electrical and mechanical systems, with a strong focus on execution and fleet impact. You will drive end to end resolution of field and manufacturing issues, from root cause through solution development, validation, release, and implementation into the manufacturing line and service fleet. You will work closely with Serviceability & Manufacturing Engineering, and cross functional partners to ensure solutions are robust, scalable, and aligned with Design for Service (DFS) and Design for Manufacturing (DFM) requirements. Your work will directly improve fleet uptime, reduce downtime drivers, and improve reliability metrics such as MTBF.Responsibilities:Own sustaining engineering support and corrective action development for the Level 3 Toyota Highlander test and mapping fleet across OEM vehicle systems and Zoox integrated AV hardware, from root cause confirmation through fleet wide implementationDrive end to end resolution of vehicle and AV system issues, including diagnosis, troubleshooting, root cause analysis, solution development, validation, release, and implementation into the service fleetLead design updates and improvements for Zoox and Toyota components and subsystems to improve reliability, durability, fleet availability, and serviceability across electrical and mechanical systemsAuthor and manage Engineering Change Requests and Change Actions, develop and execute validation and test plans, and lead fleet trials to verify long term effectiveness of implemented changesSupport retrofit campaigns, rework activities, installation trials, and field failure triage, partnering with service, test, and operations teams to restore vehicles to service quickly and effectivelyPartner with suppliers, Manufacturing, and Serviceability Engineering to deliver durable, manufacturable, and serviceable solutions that meet Design for Service and Design for Manufacturing requirementsApply fleet data, technician feedback, and reliability metrics such as MTBF and repeat failure trends to prioritize work, validate corrective actions, and prevent recurrenceRequirements:BS in Mechanical Engineering, Electrical Engineering, or related discipline, MS preferred5+ years of experience in electrical and mechanical systems engineering within a product development, manufacturing, or sustaining environmentDemonstrated ability to deliver subsystem level reliability or serviceability improvements using root cause analysis, DFMEA, and validation testingHands on experience using tools such as Python, SQL, Vector CANalyzer, or Databricks to access fleet data, parse logs, review telemetry, and support issue diagnosis and validationStrong communication and documentation skills, proficiency with 3D CAD tools such as CATIA, and ability to work cross functionally in a fast paced environment managing multiple prioritiesBonus Qualifications:Experience with EV architectures, high voltage systems, or autonomous vehicle platformsBackground in Toyota or OEM vehicle development and release processesFamiliarity with electrical design tools and fleet data analysis or visualization tools