An advanced manufacturing company is scaling a next-generation Li-ion battery and energy storage manufacturing platform in the United States and is seeking a Director of Process Engineering to lead manufacturing process development and scale-up.
This organization is focused on high-performance energy storage systems designed for defense, aerospace, and mission-critical applications, including autonomous systems, advanced mobility platforms, and other high-reliability technologies. Their products emphasize energy density, durability, safety, and performance in demanding operating environments, with a strong commitment to domestic manufacturing and secure supply chains.
This is a rare opportunity to play a key role in building and scaling a greenfield battery manufacturing operation supporting technologies critical to national security and advanced industrial innovation.
The Role
The Director of Process Engineering will lead all aspects of process development, manufacturing scale-up, and continuous improvement across battery assembly, integration, and testing operations.
This role is responsible for building robust, scalable manufacturing processes, optimizing performance across key metrics such as yield, throughput, cycle time, and cost, and leading a high-performing engineering team in a fast-paced production ramp environment.
Key Responsibilities:
Process Development & Manufacturing Scale-Up
- Lead development and industrialization of lithium ion battery assembly, cell integration, and testing processes
- Drive process scale-up from pilot to high-volume production, ensuring repeatability and stability
- Define and control critical process parameters (CPPs) and key process variables
- Support new product introduction (NPI) and ensure smooth transition into production
- Develop scalable process architectures to support capacity expansion and multi-line manufacturing
Manufacturing Optimization & Continuous Improvement:
- Improve operational performance across yield, scrap reduction, cycle time, throughput, and cost efficiency
- Lead continuous improvement using Lean Manufacturing, Six Sigma, SPC, and root cause analysis
- Utilize tools such as FMEA, control plans, Gage R&R, and statistical analysis tools (e.g., Minitab)
- Implement data-driven manufacturing systems, KPI dashboards, and process monitoring tools
Equipment & Process Integration:
- Lead equipment commissioning, qualification, and ramp-up for manufacturing systems
- Ensure alignment between process engineering, automation systems, and production equipment
- Collaborate with equipment vendors, integrators, and internal engineering teams
- Support process validation (IQ/OQ/PQ) and readiness for full-scale production
Supplier & Material Integration:
- Partner with supply chain and quality teams to manage incoming material variability and supplier performance
- Ensure successful integration of externally supplied components and materials into production processes
- Drive improvements in material quality, traceability, and process consistency
Leadership & Organizational Development:
- Build, lead, and develop a high-performing process engineering team
- Establish scalable engineering systems, standards, and best practices
- Foster a culture of accountability, innovation, and operational excellence
Strategic & Cross-Functional Leadership:
- Collaborate with Quality, Operations, Engineering, and Supply Chain to ensure alignment across the value stream
- Support capacity planning, capital investment, and long-term manufacturing strategy
- Align process engineering initiatives with overall business and production objectives
Qualifications:
- Bachelor’s degree in Engineering or related technical field
- 10+ years of experience in manufacturing or process engineering, including leadership experience
- Experience in lithium-ion (Li-ion) battery manufacturing, manufacturing engineering, or advanced manufacturing environments strongly preferred
- Experience in high-volume or high-precision manufacturing environments (battery, electronics, aerospace, semiconductor, advanced materials, etc.)
- Expertise in process improvement methodologies (Lean, Six Sigma, SPC, APQP, FMEA)
- Proven ability to scale manufacturing processes and drive operational performance improvements
- Experience in fast-paced, high-growth, or greenfield manufacturing environments
Preferred:
- Experience in lithium-ion battery manufacturing, energy storage systems, or electrification technologies
- Background in defense, aerospace, or high-reliability manufacturing environments
- Experience with automated manufacturing systems, precision assembly, or advanced production technologies
- Advanced degree (MBA or Engineering) preferred
Why This Role:
This is an opportunity to lead process engineering for a next-generation battery manufacturing platform, playing a key role in production ramp, process scalability, and long-term operational excellence in a high-growth environment.
