Battery Pack Assembly Operations Leader

American Lithium Energy (ALE); San Diego (CA); On-site; USD 180,000 - 230,000; Full time

Job summary

American Lithium Energy Corporation seeks a Battery Pack Assembly Operations Manager to lead and scale pack assembly, driving safety, quality, delivery, and productivity on the manufacturing floor. You will shepherd NPI/industrialization from prototype through ramp, build capacity and processes, and ensure AS9100D compliance and traceability.

Requires a Bachelor’s degree and 8+ years in manufacturing with 5+ years leading battery-pack teams; strong Lean, PFMEA, Control Plans, and leadership

Qualifications

• 8+ years in manufacturing with 5+ years leading battery-pack manufacturing teams.
• Experience leading pack assembly, NPI/industrialization, production ramp, capacity planning.
• Hands-on knowledge of lithium-ion pack architecture, assembly equipment/tooling, welding, BMS integration, thermal management.
• Working knowledge of AS9100 requirements, controlled documentation, traceability, nonconformance/CAPA, audits.
• Strong Lean manufacturing, PFMEA, Control Plans, 5-Why, 8D, and root cause analysis.

Responsibilities

• Lead daily battery pack assembly operations and production schedules to achieve safety, quality, delivery, cost, and productivity targets.
• Own pack manufacturing processes including cell preparation and traceability, module/pack assembly, busbar and electrical connections, welding, torque-controlled assembly, BMS/harness integration, thermal components, insulation, sealing, enclosure assembly, labeling, and final assembly.
• Lead NPI/industrialization from prototype through ramp and support DFMA, PFMEA, Control Plans, work instructions, routings, CTQs, and production-readiness reviews.
• Develop pack assembly capacity, staffing, floor-space, equipment, tooling, automation, and capital plans to meet demand and growth.
• Define and improve assembly equipment, fixtures, jigs, welding systems, torque tools, dispensing systems, material handling, and error-proofing; support commissioning, qualification, validation, and production handover.
• Ensure Pack Assembly compliance with AS9100D, including documentation control, configuration/change control, traceability, training records, nonconformance, corrective actions, and audit readiness.
• Drive manufacturing quality through FPY improvement, defect prevention, CAPA, root cause analyses, and effective resolution of internal and customer quality issues.
• Enforce EHS requirements and safe practices for lithium-ion batteries, high-voltage systems, welding, chemicals/adhesives, ergonomics, and pack/material handling.
• Build standardized work, Lean, 5S, visual management, line balancing, poka-yoke, and continuous-improvement practices to improve cycle time, labor productivity, yield, and cost.
• Build, train, and develop Pack Assembly leads, technicians, and operators; establish skill matrices, certification requirements, cross-training, and clear performance accountability.
• Maintain robust manufacturing traceability and support ERP/MES data collection for cells, modules, packs, components, process parameters, torque/weld records, material lots, and serial numbers.
• Develop, track and report KPIs including safety, OTD, schedule attainment, FPY/yield, scrap/rework, labor productivity, cycle time, throughput, OEE, downtime, and capacity utilization; develop recovery plans.

Skills

Lean manufacturing

Leadership

Problem-solving

Cross-functional collaboration

Continuous improvement

Root cause analysis

PFMEA

8D

BMS integration

Education

Bachelor’s degree in Mechanical, Electrical, Manufacturing, or Industrial Engineering

Tools

ERP/MES systems

Job description

American Lithium Energy Corporation seeks a Battery Pack Assembly Operations Manager to lead and scale pack assembly, driving safety, quality, delivery, and productivity on the manufacturing floor. You will shepherd NPI/industrialization from prototype through ramp, build capacity and processes, and ensure AS9100D compliance and traceability.

Requires a Bachelor’s degree and 8+ years in manufacturing with 5+ years leading battery-pack teams; strong Lean, PFMEA, Control Plans, and leadership