Battery Process Engineer

1. Primary Responsibilities

1.1 Battery Supplier Development Engineer

Supplier Evaluation and Process Development:

Conduct comprehensive assessments of battery suppliers, evaluating process capabilities, manufacturing readiness, and technical competencies.

Work with suppliers to optimize key manufacturing processes such as slurry mixing, electrode coating, calendaring, stacking, electrolyte filling, formation, and aging.

Analyze process parameters, material interactions, and manufacturing conditions to improve yield, reliability, and scalability.

Identify and document potential risks, process inefficiencies, and areas for improvement to enhance overall supplier performance.

Battery Cell Design Optimization:

Collaborate with R&D and manufacturing teams to refine battery cell architecture, electrode formulations, and electrolyte compositions for better manufacturability and performance.

Conduct Design of Experiments (DOE) and statistical analysis to optimize separator selection, gas generation control, electrolyte wetting, and cycle life.

Ensure cell design changes are validated for scalability, process capability (CPK), and reliability before implementation.

Work with suppliers to validate electrode thickness control, adhesion properties, and uniformity in coating and calendaring.

Process Qualification and Production Readiness:

Define and implement process validation protocols (IQ/OQ/PQ) to ensure stable and repeatable manufacturing processes.

Develop scalable process control strategies, monitoring critical process parameters (CPPs) to minimize variation.

Support suppliers in meeting manufacturing readiness criteria for EVT/DVT/PVT builds, ensuring adherence to quality, performance, and yield expectations.

Assist in supplier-driven process improvements, leveraging SPC, DOE, and root cause analysis to resolve process issues.

Yield Improvement and Failure Analysis:

Monitor supplier performance metrics, including defect rates, inline inspection data, and yield trends.

Lead root cause analysis (RCA) and corrective action implementation (8D, CAPA) to address process failures and non-conformities.

Utilize AOI (Automated Optical Inspection), CT scanning, and in-line metrology to detect and mitigate manufacturing defects.

Support failure mode analysis and moisture control improvements to ensure long-term battery reliability.

1.2 Additional Responsibilities

While the primary focus of this role is process development and supplier collaboration, the SDE will also contribute in the following areas:

Project Management: Support or lead projects related to battery manufacturing efficiency, process optimization, and cost reduction.

Process Automation & Efficiency: Collaborate with suppliers to evaluate automation opportunities, improving yield and production scalability.

Advanced Metrology & Quality Control: Work with suppliers to implement real-time monitoring, AOI, and advanced inspection methodologies.

Reliability & Safety Testing: Assist in defining test methodologies for evaluating battery performance, abuse tolerance, and degradation mechanisms.

2. Deliverables

Manufacturing Process Qualification: Develop and implement scalable processes, ensuring suppliers meet build readiness gates for EVT/DVT/PVT.

Process Control & Monitoring: Establish SPC-based process controls for critical manufacturing parameters.

Battery Cell Optimization: Conduct DOE-driven studies to refine cell design, electrode processing, and formation cycling protocols.

Yield & Defect Reduction: Identify key defect modes, implement corrective actions, and track CPK improvements.

Manufacturing Readiness & Supplier Engagement: Support suppliers in achieving process stability and meeting ramp-up criteria.

Failure Analysis & Continuous Improvement: Implement RCA, CAPA, and FMEA methodologies to improve process stability and defect prevention.

Daily/Weekly Updates: Effectively communicate supplier readiness and build status, as well as any other urgent issues and needs to team members

Audit: Conduct supplier audits and drive continuous improvement initiatives to enhance supplier performance

Other Responsibilities: include but are not limited to

2D Process and Design Review: Support battery cell and module design review to ensure manufacturability and process compatibility.

Process Documentation & Work Instructions: Define and maintain standard process documentation and best practices for supplier manufacturing.

Process Qualification & Optimization: Define process validation strategies, cycle time reduction, and waste minimization initiatives.

Reliability & ORT (Ongoing Reliability Testing) Design & Execution: Develop long-term reliability validation protocols for improved product lifespan.

Material & Component Specification Optimization: Establish material requirements for separators, cathodes, and anodes based on performance and processability.

Yield Bridge & Statistical Process Control (SPC): Track supplier yield loss trends and implement continuous process improvement strategies.

Process Control & Monitoring Systems Setup: Establish real-time process monitoring and feedback loops to detect deviations early.

Scalability & Cost Reduction Initiatives: Work with suppliers to enhance process scalability while optimizing production costs.

Ensuring First Article Inspection (FAI) and CPK Compliance: Validate supplier capability to meet production requirements with high process stability.