Battery Pack Assembly Technician

Job Purpose

The Battery Pack Assembly Technician builds lithium-ion battery modules and packs in accordance with approved work instructions, engineering drawings, bills of material specifications, and safety requirements. The technician is responsible for accurate traceable, and conforming electromechanical assemblies while meeting established safety, quality, and productivity expectations within ALE’s AS9100D Quality Management System.

Essential Duties and Responsibilities

• Assemble battery modules and packs using approved tools, fixtures, work instructions, drawings, bills of material, and production travelers.
• Install cells or modules, busbars, battery management system components, wiring harnesses, connectors, fuses, sensors, insulation, thermal interface materials, enclosures, fasteners, labels, and related hardware.
• Perform approved soldering, crimping, adhesive application, sealing, ultrasonic or resistance welding, and torque-controlled fastening after completing required training and qualification.
• Verify material identity, lot or serial numbers, shelf life, revision level, tool calibration status, polarity, orientation, routing, torque values, and workmanship at required process steps.
• Perform in process inspections and basic electrical or functional checks using approved test equipment and procedures; accurately record results and immediately escalate failures or abnormal conditions.
• Complete production travelers, electronic records, material transactions, inspection results, and traceability documentation accurately and in real time.
• Identify, segregate, label, and report nonconforming material. Do not perform unauthorized rework, deviation, or substitution.
• Follow ESD, FOD, chemical handling, lockout tagout, and lithium-ion battery safety requirements, including response procedures for damaged, leaking, hot, swollen, or suspect cells and packs.
• Maintain a clean, organized, and audit ready work area using 5S practices; protect product from contamination, damage, and foreign objects.
• Meet production schedule, quality, and productivity targets; communicate shortages, equipment issues, documentation discrepancies, and safety concerns promptly.
• Support training, cross training, continuous improvement, inventory counts, and other pack assembly activities consistent with the role and the employee's documented qualifications.

Qualifications

• High school graduate or equivalent.
• At least one year of experience in manufacturing, production assembly, electronics assembly, mechanical assembly, or a related environment.
• Ability to read and follow written work instructions, assembly drawings, bills of material, specifications, labels, and safety procedures in English.
• Strong attention to detail, manual dexterity, and ability to work with small components, hand tools, calibrated tools, fixtures, and semi-automated equipment.
• Basic computer skills and ability to enter accurate information in electronic manufacturing or inventory systems.
• Ability to work effectively in a team, communicate concerns promptly, and maintain reliable attendance in a schedule driven production environment.

Preferred Qualifications

• Technical certificate, vocational training, or associate degree in electronics, manufacturing, mechanical technology, or a related field.
• Experience assembling lithium-ion battery modules or packs, aerospace or defense products, electronics, or other complex electromechanical products.
• Experience in an AS9100D, ISO 9001, aerospace, defense, automotive, medical device, or similarly regulated manufacturing environment.
• Experience with torque-controlled assembly, wiring, crimping, soldering, welding, adhesives, sealants, electrical testing, production travelers, and material traceability.
• Current or prior IPC J STD 001, IPC WHMA A 620, welding, soldering, ESD, or related industry certification.

Work Environment

Work is performed in a lithium-ion battery manufacturing environment near energized electrical systems, production equipment, adhesives, solvents, and regulated materials. The employee must follow posted safety and emergency procedures, and wear assigned personal protective equipment, which may include safety glasses, gloves, safety footwear, antistatic protection, protective clothing, face protection, or respiratory protection based on the documented hazard assessment.

• Stand and walk for extended periods and perform repetitive hand, wrist, and arm movements.
• Frequently handle small components, tools, fixtures, and production documentation; bend, stoop, squat, reach, push, and pull as required.
• Safely lift and carry materials or equipment weighing up to 35 pounds, with assistance or lifting equipment when required.
• Maintain the visual acuity, color recognition, and manual dexterity needed for detailed assembly and inspection work.

Physical Requirements

The employee must be able to perform the essential functions of the position, with or without reasonable accommodation, including:

• Standing and walking for extended periods during the work shift.
• Frequently use hands and fingers to handle small components, tools, fixtures, and production documentation.
• Performing repetitive hand, wrist, and arm movements.
• Bending, stooping, squatting, reaching, pushing, and pulling as required.
• Safely lifting and carrying materials or equipment weighing up to 35 pounds.
• Maintaining the visual acuity and manual dexterity necessary to perform detailed assembly and inspection work.
• Wearing required personal protective equipment for the duration required by the assigned task or work area.

Pay: $20.50 - $24.00 per hour

Expected hours: 40.0 per week

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Employee assistance program
• Employee discount
• Flexible spending account
• Health insurance
• Health savings account
• Life insurance
• On-the-job training
• Paid sick time
• Paid time off
• Vision insurance

Experience:

• Manufacturing: 1 year (Required)
• Assembly: 1 year (Required)
• Computer skills: 1 year (Required)
• AS9100: 1 year (Required)
• Quality inspection: 1 year (Required)
• Soldering: 1 year (Required)

Shift availability:

• Day Shift (Required)

Work Location: In person