Senior Staff Customer Quality Engineer

NextGenEnergyJobs; Canada; Hybrid; CAD 156,000 - 197,000; Full time

Job summary

NextGenEnergyJobs is seeking a senior Quality Leader to oversee IQC, IPQC, OQC, and ORT across battery cell production lines in Canada. You will drive readiness for EVT/DVT/PVT and scale to mass production with CM partners, leading RCCA investigations and implementing robust quality systems.

You will collaborate with cell engineering to define QC stations, establish metrology standards, monitor electrochemical quality metrics, and manage safety and certification compliance.

Qualifications

• Minimum of 12 years of related experience with a Bachelor’s degree; or 8 years and a Master’s degree; or a PhD with 5 years experience; or equivalent experience.
• Hands-on experience in lithium-ion cell manufacturing processes and product qualification
• Familiarity with battery-specific metrology: coating weight, electrode thickness and density, porosity, tab alignment, and electrolyte fill weight measurement and control
• Strong command of quality and problem-solving tools: DOE, RCCA/8D, SPC, GR&R/MSA, PFMEA, control plans, and capability analysis (Cpk/Ppk)
• Knowledge of reliability methods relevant to batteries: Weibull analysis, HALT/HASS, accelerated life testing, and electrochemical failure mode characterization
• Familiarity with GD&T, tolerance stack-up analysis, and metrology best practices in a precision manufacturing context
• Experience managing CM/OEM quality relationships in Asia; ability to navigate cultural and organizational dynamics effectively
• Track record of developing manufacturing process documentation that captures process rationale, critical control points, failure modes and equipment constraints.

Responsibilities

• Manage IQC, IPQC, OQC, and ORT across battery cell production lines
• Drive quality readiness at the CM for development builds (EVT/DVT/PVT) and mass production ramp, including establishing inspection and hold/release protocols
• Lead RCCA investigations for quality escapes; present findings and closure plans to internal and CM leadership as required
• Collaborate with cell engineering and teams to define and implement appropriate quality control, inspection, and metrology stations across the full cell production process
• Define and monitor electrochemical quality metrics, identify process signals and drive SPC implementation
• Conduct periodic factory quality reviews covering yield, scrap, defect Pareto, and process capability trends
• Prepare OK-to-Ship and lot dispositioning documentation for new product launch and ongoing mass production
• Develop and maintain risk assessments (PFMEA) for battery manufacturing processes; implement control plans and reaction plans for identified risk items
• Support DFM reviews with cell design and product teams; conduct tolerance analysis for electrode stack, cell can/pouch dimensions, and assembly fit to ensure process capability against specification
• Develop and execute module and cell reliability test plans (cycle life, calendar aging, thermal abuse, mechanical) during NPI and MP, in coordination with internal engineering teams
• Ensure manufacturing process controls are sufficient to maintain compliance with applicable safety and certification standards (IEC 62133, UN 38.3, UL 1642, GB/T equivalents as applicable) at the production level
• 30–40% international travel to CM sites in Asia required

Education

Bachelor’s degree in engineering or related field

Master’s degree in engineering or related field

PhD with 5 years experience

Tools

DOE

RCCA/8D

SPC

GR&R/MSA

PFMEA

Control plans

Capability analysis (Cpk/Ppk)

GD&T

Job description

The starting base pay for this role is between $156,000 and $197,000 at the time of posting.

Key Responsibilities

• Manage IQC, IPQC, OQC, and ORT across battery cell production lines
• Drive quality readiness at the Contract Manufacturer (CM) for development builds (EVT/DVT/PVT) and mass production ramp, including establishing inspection and hold/release protocols
• Lead root cause and corrective action (RCCA) investigations for quality escapes; present findings and closure plans to internal and CM leadership as required
• Collaborate with cell engineering and teams to define and implement appropriate quality control, inspection, and metrology stations across the full cell production process (electrode coating and calendering, winding/stacking, electrolyte filling, formation, aging, and final test)
• Define and monitor electrochemical quality metrics, identify process signals and drive SPC implementation
• Conduct periodic factory quality reviews covering yield, scrap, defect Pareto, and process capability trends
• Prepare OK-to-Ship and lot dispositioning documentation for new product launch and ongoing mass production
• Develop and maintain risk assessments (PFMEA) for battery manufacturing processes; implement control plans and reaction plans for identified risk items
• Support DFM reviews with cell design and product teams; conduct tolerance analysis for electrode stack, cell can/pouch dimensions, and assembly fit to ensure process capability against specification
• Develop and execute module and cell reliability test plans (cycle life, calendar aging, thermal abuse, mechanical) during NPI and MP, in coordination with internal engineering teams
• Ensure manufacturing process controls are sufficient to maintain compliance with applicable safety and certification standards (IEC 62133, UN 38.3, UL 1642, GB/T equivalents as applicable) at the production level
• 30–40% international travel to CM sites in Asia required

Requirements

• In this highly visible role, you will have the opportunity to make a significant impact on next-generation battery products and establish quality systems that scale from development through high-volume production. You will serve as the critical bridge between our internal cell engineering and product teams and the factory floor—enabling the reliable, high-yield manufacture of advanced battery cells.
• Minimum of 12 years of related experience with a Bachelor’s degree; or 8 years and a Master’s degree; or a PhD with 5 years experience; or equivalent experience.
• Hands-on experience in lithium-ion cell manufacturing processes and product qualification
• Familiarity with battery-specific metrology: coating weight, electrode thickness and density, porosity, tab alignment, and electrolyte fill weight measurement and control
• Strong command of quality and problem-solving tools: DOE, RCCA/8D, SPC, GR&R/MSA, PFMEA, control plans, and capability analysis (Cpk/Ppk)
• Knowledge of reliability methods relevant to batteries: Weibull analysis, HALT/HASS, accelerated life testing, and electrochemical failure mode characterization
• Familiarity with GD&T, tolerance stack-up analysis, and metrology best practices in a precision manufacturing context
• Experience managing CM/OEM quality relationships in Asia; ability to navigate cultural and organizational dynamics effectively
• Track record of developing manufacturing process documentation that captures process rationale, critical control points, failure modes and equipment constraints.
• Working knowledge of battery safety standards and certification pathways (IEC, UL, GB/T, KC, PSE)
• Strong cross-functional communication skills; comfortable presenting technical findings to engineering and executive audiences