Define and optimize pouch cell and module assembly processes, including electrode handling, notching, stacking, welding, pouch formation and sealing, electrolyte filling, formation, and final inspection.
Develop standard operating procedures (SOPs), work instructions, and process flow diagrams for all critical manufacturing steps.
Implement lean manufacturing, Six Sigma, and DOE (Design of Experiments). methodologies to improve process stability and efficiency.
Identify and mitigate process bottlenecks to achieve high yield and low defect rates.
Work with equipment vendors to define process requirements, FAT, SAT, and commissioning plans.
Support equipment qualification (IQ/OQ/PQ) and ensure seamless integration of semi-automated assembly and formation systems.
Collaborate with the automation and maintenance teams to fine-tune machine parameters and control strategies.
Develop and implement process control strategies to ensure consistent cell performance and reliability.
Conduct root cause analysis (RCA) and corrective actions for quality defects such as delamination, electrolyte leakage, or tab welding inconsistencies.
Work closely with the quality team to ensure compliance with ISO 9001, UL2580, and safety regulations.
Utilize SPC (Statistical Process Control) and FMEA to identify and address process risks.
Collaborate with R&D, automation, and production teams to scale up new cell and module designs and manufacturing processes.
Develop and maintain process documentation, including work instructions, troubleshooting guides, and technical reports.
Strong understanding of lithium-ion cell and module manufacturing processes.
Hands-on experience with semi-automated cell and module assembly equipment.
Expertise in process validation, statistical process control (SPC), and DOE (Design of Experiments).
Proficiency in data analysis tools for process optimization.
Knowledge of ISO 9001, and APQP (Advanced Product Quality Planning).
Familiarity with the material properties of lithium-ion components (electrolyte, separator, cathode/anode materials) and their impact on process parameters.
Soft Skills and Experience:
Bachelor’s or Master’s degree in Chemical Engineering, Mechanical Engineering, Materials Science, or a related field.
5+ years of experience in lithium-ion battery manufacturing or a similar high-precision industry (semiconductors, automotive, electronics).
Strong problem-solving skills with a hands-on approach to process troubleshooting and optimization.
Ability to work cross-functionally with engineering, production, and quality teams.
Experience with FMEA, Lean, Six Sigma (Green Belt or higher preferred).
Hands-on experience in pouch cell production.
Experience with semi-automated manufacturing lines and Industry 4.0 initiatives.
Prior involvement in FAT, SAT, and commissioning of lithium-ion battery equipment.
Experience in thermal management, gas formation control, and electrochemical performance testing.