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 Principal Manufacturing Engineer will serve as the technical and managerial lead for manufacturing processes at the Lithium Gigafactory, combining expert technical knowledge with strong leadership capabilities. This role is responsible for overseeing the design, optimization, and scaling of manufacturing processes for lithium-ion cells, while also managing a team of engineers and cross-functional collaborators. You will drive innovation, ensure production excellence, and lead strategic projects that align with company objectives. In addition to technical oversight, you will be responsible for mentoring and developing team members, managing resources, and ensuring the smooth operation of day-to-day manufacturing activities.

Essential Duties and Responsibilities

Strategic Leadership in Manufacturing:

Lead the development and implementation of advanced manufacturing processes for lithium-ion cells, focusing on improving energy density, safety, cost efficiency, and scalability. Set long-term strategies for process optimization, ensuring alignment with company goals for product performance, cost, and operational efficiency. Oversee the introduction of new technologies, materials, and manufacturing techniques, leveraging data-driven insights and simulation tools.

Managerial and Supervisory Responsibilities:

Manage a team of engineers, including recruitment, training, performance evaluations, and career development. Provide day-to-day leadership and support for engineering staff, assigning tasks, monitoring progress, and ensuring project deadlines and milestones are met. Foster a collaborative and inclusive team culture focused on innovation, continuous improvement, and professional growth. Ensure clear communication and alignment of goals across the team, offering mentorship and technical guidance as needed.

Project and Program Management:

Lead large-scale, high-impact manufacturing projects, overseeing resource allocation, budgeting, and scheduling. Coordinate with cross-functional teams, including R&D, product development, and supply chain, to ensure timely and successful project completion. Serve as the primary point of contact for senior leadership on manufacturing initiatives, providing updates on project progress, KPIs, and strategic recommendations.

Process Innovation and Optimization:

Spearhead initiatives to enhance manufacturing efficiency, reduce production costs, and improve the overall performance and reliability of lithium-ion cells. Identify and implement cutting-edge automation solutions, advanced materials, and manufacturing processes. Oversee pilot-scale production and manage the transition of new processes to full-scale manufacturing operations.

Quality Assurance and Compliance:

Ensure that all manufacturing processes adhere to industry regulations (e.g., UN/DOT, IEC, ISO) and internal quality standards. Work with quality assurance teams to address production or performance issues and implement corrective actions to maintain product excellence. Develop and monitor key performance indicators (KPIs) for production efficiency, product quality, and process reliability.

Collaboration and Cross-Functional Engagement:

Partner with internal teams, including materials scientists, chemists, mechanical engineers, and supply chain managers, to ensure seamless integration of new designs and processes into production. Collaborate with external suppliers and partners to optimize materials and components for the lithium-ion manufacturing process.

Continuous Improvement and Sustainability:

Lead continuous improvement initiatives focused on enhancing product quality, safety, and sustainability, while minimizing costs and environmental impact. Drive efforts to reduce waste, improve energy efficiency, and implement eco-friendly manufacturing practices within the plant.

Supervisory and Team Leadership:

Act as a mentor to mid-level and senior engineers, developing their technical and leadership skills while fostering a culture of collaboration and innovation. Set performance goals for team members, conduct regular performance reviews, and provide constructive feedback and development plans. Promote a safe working environment and ensure compliance with all safety regulations and best practices. Travel Expectations

There will be a 50% travel requirement for the first year of employment and then 25% thereafter on an ongoing basis. You must be able to travel domestically and internationally.

Minimum Qualifications

 

Bachelor’s Degree in Mechanical, Electrical, Materials, or Chemical Engineering (or equivalent). Master’s or Ph.D. in a relevant field preferred. 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 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 (e.g., UN/DOT, IEC, ISO) related to lithium-ion cells. Excellent leadership, communication, and problem-solving skills, with experience in managing and developing engineering teams. Demonstrated ability to drive continuous improvement and implement innovative solutions in a fast-paced manufacturing environment. Preferred Qualifications Advanced Degree: Master’s or Ph.D. in Mechanical, Electrical, Materials, or Chemical Engineering, with a focus on energy storage or electrochemical systems. Extensive Lithium-Ion Experience: 12+ years of experience in the lithium-ion battery industry, particularly in the design, development, and scale-up of cell manufacturing processes. 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 navigating complex regulatory environments, including deep familiarity with international standards such as UN/DOT 38.3, IEC 62133, ISO 9001/14001, and related certifications. Lean Manufacturing and Six Sigma: Certifications in Lean Manufacturing, Six Sigma (Green or Black Belt), or equivalent methodologies with a proven track record of process optimization and waste reduction. Global Manufacturing Experience: Experience working in a global manufacturing environment, including managing cross-cultural teams and coordinating with international suppliers and production facilities. Technical Publications and Patents: Proven track record of contributing to the field through published research papers, patents, or innovations in lithium-ion battery manufacturing technologies. Project Management Certification: PMP (Project Management Professional) or similar project management certification, highlighting your ability to manage large-scale, complex projects. Advanced Data Analysis Skills: Experience with advanced data analytics tools (e.g., Python, MATLAB, or similar) and statistical analysis software (e.g., Minitab) to support data-driven decision-making and process improvement.
  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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