Process Development Engineer, Battery Assembly

A day in the role

You begin the morning with the production team, walking the line to confirm processes are safe, stable, and meeting takt. A bottleneck emerges at a test station—by midday, you’ve isolated the root cause, issued a corrective action, and updated standard work. In the afternoon, you host a pilot build review for a new battery pack variant, aligning with Product Engineering to validate manufacturability before the next ramp.

Purpose of the position

Own the creation, deployment, and continuous refinement of end-to-end assembly processes for battery modules and packs. Ensure operations are safe, efficient, repeatable, and faithful to engineering intent—supporting facility launch, volume acceleration, and long-term scalability.

Reporting and collaboration

• Reports to: Director of Manufacturing
• Partners closely with: Production Supervisors and Operators; Product Engineering (Electrical, Mechanical, Thermal); Product Integration; Quality; EHS
• Primary focus: Process design, line support, and continuous improvement

What you will build and improve

1) Manufacturing process development

• Design and document complete manufacturing flows for battery module and battery pack assembly
• Define process sequence and work content to achieve quality, throughput/takt, and safety/ergonomic targets

2) Standard work and instructions

• Create and maintain detailed work instructions, visual aids, and standard work documents
• Ensure alignment to drawings and BOMs, current revisions, and approved changes
• Train production personnel on new or revised procedures

3) Equipment, tooling, and fixtures

• Specify, install, commission, and support assembly tools/fixtures, test and inspection equipment, and material handling aids
• Validate production equipment and document settings

4) Line launch and ramp support

• Provide hands-on support for initial line start-up, volume ramp, and new product or variant introductions
• Serve as first responder to process issues, bottlenecks, and downtime; implement corrective actions to stabilize output

5) Quality and process control

• Define in-process checks, error-proofing (poka-yoke), and process capability/control plans
• Partner with Quality on root cause analysis and CAPA

6) Engineering change and NPI

• Assess manufacturability impacts and update processes/instructions as designs evolve
• Prepare for NPI by supporting pilot builds and enabling a smooth handoff from engineering to production

7) Continuous improvement and cost

• Lead initiatives that raise yield, reduce cycle time, improve labor efficiency, and cut scrap/rework
• Apply lean principles to streamline flow and boost productivity

8) Safety and ergonomics

• Ensure processes meet EHS requirements and safe work practices
• Identify and mitigate ergonomic and safety risks in assembly and material handling

9) Documentation, metrics, and reporting

• Maintain accurate process definitions, equipment settings, and change history
• Track and report key process metrics for operational decision-making

Daily rhythm

• Support the production floor and troubleshoot process/equipment issues
• Update work instructions and documentation
• Participate in improvement events and assist with line balancing and staffing adjustments
• Coordinate with engineering and quality teams

Deliverables you own

• Process flows and layouts
• Standard work and work instructions
• Tooling and equipment specifications
• Continuous improvement plans and outcomes
• Inputs to production readiness and launch reviews

Authority and boundaries

• Authority to define and enhance manufacturing processes
• No authority over product design decisions
• Required to promptly escalate safety, quality, or capacity risks

How success is measured

• Process stability and repeatability
• First-pass yield and defect reduction
• Throughput versus takt-time performance
• Downtime and rework reduction
• Effectiveness of NPI transitions

Why this role matters

In battery manufacturing, small misses can multiply quickly. Early instability erodes margins. Robust processes safeguard quality and safety. This role ensures the factory is engineered—not improvised—so growth is predictable and customers trust the product.

What you know

• Industrial and Manufacturing Engineering
• 5 Why root cause analysis
• Process Engineering
• Machine setup for production runs
• Process development
• CAPA
• Cycle time optimization
• Line launch
• Production line setup