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Six Sigma

About the job

EnerSys is a 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 Process Engineer, Slurry Mixing - Battery Cells is responsible for the development, optimization, industrialization, and scale-up of slurry mixing processes used in lithium-ion battery cell manufacturing. This role supports both anode and cathode slurry preparation and is responsible for ensuring consistent material quality, robust manufacturing performance, and readiness for high-volume production. The position works closely with Engineering, Manufacturing, Quality, Maintenance, Automation, EHS, Product Development, suppliers, and technology partners to establish and sustain world-class slurry mixing processes from pilot development through commercial production. The successful candidate combines strong process engineering expertise with a hands-on approach to manufacturing excellence and continuous improvement.

Essential Duties and Responsibilities

Develop, optimize, and industrialize slurry mixing processes for lithium-ion battery cell manufacturing, supporting both anode and cathode formulations.

Define and control process parameters related to raw material dosing, binder dissolution, dispersion, kneading, degassing, filtration, intermediate storage, and slurry transfer operations.

Support equipment specification, supplier selection, technical evaluations, RFQ development, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, and production startup activities.

Establish and maintain process windows for critical slurry quality characteristics, including viscosity, density, solids content, temperature, homogeneity, dispersion quality, and rheological behavior.

Plan, execute, and analyze laboratory, pilot-scale, and production trials to support process development and manufacturing scale-up.

Implement process control strategies, inline quality monitoring systems, contamination prevention measures, cleaning protocols, magnetic filtration systems, and waste reduction initiatives.

Develop and maintain process documentation including process flow diagrams, work instructions, validation protocols, technical specifications, control plans, and PFMEA documentation.

Analyze process performance data, identify root causes of process variation, and implement corrective actions to improve yield, throughput, OEE, and process capability.

Collaborate closely with electrode manufacturing, coating, quality, production, maintenance, automation, EHS, and external equipment suppliers.

Support continuous improvement activities focused on quality, efficiency, cost reduction, operational excellence, and manufacturing readiness.

Ensure compliance with all applicable safety, environmental, quality, cleanliness, and dry-room manufacturing requirements.

Participate in startup, commissioning, validation, and technology transfer activities supporting Gigafactory deployment and operational readiness.

Qualifications

Bachelor's degree in Chemical Engineering, Process Engineering, Materials Science, Mechanical Engineering, Battery Technology, or a related technical discipline required.

Three (3) or more years of experience in process engineering, preferably within lithium-ion battery manufacturing, electrode production, slurry mixing, coating, chemical processing, or similar advanced manufacturing industries.

Experience supporting equipment qualification, process validation, commissioning, startup, and production ramp-up activities preferred.

Experience working in high-volume manufacturing environments and process scale-up projects preferred.

Experience with MES, SCADA, process control systems, manufacturing databases, and engineering analysis tools preferred.

Experience with data collection, reporting, and process monitoring systems preferred.

Six Sigma Green Belt or Black Belt certification is preferred.

Additional manufacturing, engineering, or quality certifications are beneficial.

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.

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