Director Lithium Manufacturing Engineer at EnerSys Energy Products, Inc

EnerSys is the global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products.

Job Purpose

The Director of Manufacturing Engineering will provide strategic leadership and technical oversight for the manufacturing processes at the Lithium Gigafactory. This high-impact role requires a blend of advanced engineering expertise, innovative process development, and exceptional leadership abilities. As the leader of the manufacturing engineering team, you will drive large-scale projects, optimize manufacturing systems, and ensure the efficient production of high-performance lithium-ion cells. You will also mentor engineers, manage resources, and align manufacturing strategies with company-wide goals.

Essential Duties and Responsibilities

Strategic Leadership in Manufacturing:

• Lead the design and execution of advanced manufacturing processes for lithium-ion cells, prioritizing improvements in energy density, safety, cost efficiency, and scalability.
• Define long-term process optimization strategies to meet company objectives for product performance, cost management, and operational efficiency.
• Introduce cutting-edge technologies, materials, and manufacturing methodologies, integrating data-driven insights and advanced simulation tools.

Managerial and Supervisory Responsibilities:

• Manage and develop a team of manufacturing engineers, including recruitment, training, performance evaluations, and career development.
• Provide leadership and support to ensure team goals are met, with clear communication on progress, deadlines, and project milestones.
• Foster a collaborative, inclusive team culture that encourages continuous improvement, innovation, and professional development.

Project and Program Management:

• Lead large-scale manufacturing projects, overseeing the allocation of resources, budgeting, and scheduling to ensure timely completion.
• Act as the primary point of contact for senior leadership regarding manufacturing initiatives, providing regular updates on project progress, KPIs, and strategic recommendations.
• Collaborate with cross-functional teams, including R&D, product development, and supply chain, to ensure alignment on manufacturing objectives.

Process Innovation and Optimization:

• Spearhead initiatives to improve manufacturing efficiency, reduce costs, and enhance the performance and reliability of lithium-ion cells.
• Implement automation solutions and advanced manufacturing technologies to streamline production processes.
• Manage the transition of new manufacturing processes from pilot-scale to full-scale production.

Quality Assurance and Compliance:

• Ensure all manufacturing processes meet industry regulations (e.g., UN/DOT, IEC, ISO) and internal quality standards.
• Collaborate with quality assurance teams to resolve production or performance issues, implementing corrective actions to maintain high product standards.
• Develop and monitor key performance indicators (KPIs) for production efficiency, product quality, and process reliability.

Collaboration and Cross-Functional Engagement:

• Work closely with internal teams-such as materials scientists, chemists, and supply chain managers-to ensure seamless integration of new designs and processes into production.
• Partner with external suppliers to optimize materials and components used in lithium-ion cell manufacturing.

Continuous Improvement and Sustainability:

• Lead initiatives focused on improving product quality, safety, and sustainability while reducing costs and environmental impact.
• Implement eco-friendly manufacturing practices, driving efforts to reduce waste and improve energy efficiency within the plant.

Supervisory and Team Leadership:

• Act as a mentor for mid-level and senior engineers, promoting technical and leadership development within the team.
• Set performance goals for team members, provide regular feedback, and conduct performance reviews.
• Ensure compliance with safety regulations and foster a culture that prioritizes safety and continuous improvement.
  

Minimum Qualifications

• Bachelor's Degree in Mechanical, Electrical, Materials, or Chemical Engineering (or equivalent).
• 10+ years of experience in manufacturing engineering, with a focus on lithium-ion cell development or advanced energy storage technology.
• Proven track record in managing large, complex manufacturing projects, including resource management, budgeting, and cross-functional team leadership.
• Strong expertise in lithium-ion cell chemistry, electrode design, assembly processes, and scaling from pilot to full-scale production.
• Familiarity with industry standards and regulatory requirements (UN/DOT, IEC, ISO) related to lithium-ion cells.
• Excellent leadership, communication, and problem-solving skills, with a demonstrated ability to manage and develop engineering teams.
• Experience driving continuous improvement and implementing innovative solutions in a fast-paced manufacturing environment.
  

Travel Expectations

• There will be a 50% travel requirement for this role.

Preferred Qualifications

• Advanced Degree: Master's or PhD in Mechanical, Electrical, Materials, or Chemical Engineering, with a focus on energy storage or electrochemical systems.
• Extensive Lithium-Ion Experience: 12+ years in the lithium-ion battery industry, specifically in cell manufacturing process design, development, and scale-up.
• Deep Knowledge of Electrochemical Materials: Advanced understanding of lithium-ion battery chemistry, electrode materials (e.g., cathode, anode), electrolyte formulations, and separator technologies.
• Process Development and Scale-Up Experience: Demonstrated success in transitioning manufacturing processes from R&D to mass production, including pilot plant operations and full-scale plant setup.
• Strong Regulatory Background: Expertise in regulatory environments, including knowledge of international standards such as UN/DOT 38.3, IEC 62133, ISO 9001/14001.
• Lean Manufacturing and Six Sigma: Certifications in Lean Manufacturing, Six Sigma (Green or Black Belt), or similar methodologies with proven success in process optimization.
• Global Manufacturing Experience: Experience leading global manufacturing operations and managing cross-cultural teams.
• Technical Publications and Patents: Record of contributing to the industry through published papers, patents, or innovations in lithium-ion battery manufacturing.
• Project Management Certification: PMP (Project Management Professional) or similar certification.
• Advanced Data Analysis Skills: Experience with Python, MATLAB, or other analytics tools to support data-driven decision-making.
  

General Job Requirements

• Generic

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws. EEO/Minority/Female/Vets/Disabled

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