Manufacturing Engineer - Front-End Cell Assembly

Job Description

Job Responsibilities

• You will own end-to-end Design For Manufacturing (DFM), leading change control, process qualification, commissioning, and formal handovers for new lines, first-of-kind and duplicate equipment, retrofits, and optimization projects. Including Prototyping/FAT/SAT/GR&R/Cpk sign-off, and delivering required packages (FMEA, BOM, LOTO, SOPs, build-as-print), remain engaged post-handover for change management, OEE ramps, fleet landing plans, vendor qualification, and escalation through Change Control Boards
• Deploy, validate, and continuously optimize automated cell assembly equipment for press-fit/swaging, ultrasonic welding, laser welding, helium leak testing, hi-pot testing, and X-ray inspection. Drive process characterization, root-cause analysis (5 Whys, 8D, DMAIC), DOE, SPC, GD&T, and statistical validation to achieve process capability, high yield, and low downtime
• Partner cross-functionally with R&D, Ramp, Quality, Maintenance, Automation, and vendors to introduce new cell designs/materials, standardize handover procedures, and close outliers. Optimize cell handling, vision inspection, and joining systems for speed, precision, and repeatability
• Design and integrate advanced automation (PLCs, motion control, real-time data, error-proofing), sophisticated vision systems (Keyence/Cognex), and pneumatic/mechanical/electrical systems (Bluebeam/AutoCAD/Eplan). Develop safety solutions and culture aligned with OSHA, ISO, TUV, NFPA-70E, and IEC standards
• Lead multidisciplinary projects (NPI, CAPA, RCA, OCAP) that integrate automation, predictive analytics, and quality systems (PFMEA/DFMEA, risk assessments). Mentor teams, apply Agile/OKRs, and drive improvements in safety, people, accuracy, rate, and cost
• This role sits at the intersection of process development, equipment qualification, and production ramp, giving you direct influence on how new and existing systems come online and stay capable

Job Requirements

• Degree or Equivalent Experience in Mechanical, Manufacturing, Chemical, Materials, or Electrical Engineering (or equivalent experience) plus 5+ years in process/equipment development, preferably in lithium-ion batteries/energy storage, electronics, medical devices, automotive, or hermetic packaging. Hands-on lithium-ion cell design, assembly, testing, failure analysis, and R&D-to-production transfer. Demonstrated application of engineering fundamentals to manufacturing scale-up, including dry-room operations with dew-point control, ISO 7/8 cleanroom particle/contamination management, and electrolyte handling at ppb moisture levels
• Proven skills in DFM, equipment/tooling specification and validation, yield/cost optimization, automation integration, project management, and cross-functional collaboration. Proficiency with CAD (SolidWorks/AutoCAD/Eplan), GD&T, fixture/tooling design, statistical tools (DOE, SPC, Cpk/Ppk, Minitab/JMP), PFMEA, control plans, MSA/GR&R, IQ/OQ/PQ, FAT/SAT, Lean/Six Sigma, safety/EHS, MES/Industry 4.0 data systems, troubleshooting, and continuous improvement
• Deep technical expertise treating joining and inspection as an integrated chain: Metal forming/press-fit/swaging (interference fits, plastic deformation, force/displacement, springback, tooling/die design, press selection, in-process monitoring, common failure modes, DFM)
• Ultrasonic welding (polymer and/or metal weldability, joint/horn/anvil design, parameter windows, equipment troubleshooting, strength/hermeticity validation)
• Laser welding (fiber/disk/pulsed systems, beam delivery, thermal/HAZ control, similar/dissimilar metals and plastics, in-process monitoring, safety, and inspection)
• Complementary NDT: helium leak testing (vacuum methods, sensitivity, fixtures, GR&R), hi-pot testing (electrical safety standards, automation, failure modes), and X-ray/CT inspection (radiation safety, defect algorithms, 2D/3D, AI-assisted analysis). Emphasis on equipment specification, vendor management, automation/robotics, simulation, and closing the loop with DFM/DFR for hermeticity, electrical integrity, and internal quality
• Leadership experience guiding mid-to-large multidisciplinary teams, mentoring others, and delivering company-wide impact. Comfort with Agile, OKRs, and high-performing, fast-changing environments. Strong problem-solving, decision-making, and ability to manage multiple priorities under shifting requirements