Battery Supplier Development Engineer

Job Description
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.