Battery Pack Process Engineer: Scale, Optimize & NPI

PAC Group; San Francisco (CA); On-site; CAD 206,000 - 221,000; Full time

Job summary

The PAC Group is seeking an experienced Battery Pack Process Development Consultant to support the development and optimization of manufacturing processes for advanced battery pack systems. This role will focus on improving production efficiency, quality, and scalability for battery pack assembly while collaborating with cross-functional engineering and manufacturing teams.

You will lead process design, validation, and continuous improvement initiatives, implement DFМ and scalability strategies,

Qualifications

• Bachelor’s degree in Mechanical, Electrical, Manufacturing Engineering or related field.
• Proven experience in battery pack manufacturing or process development.
• Strong knowledge of battery systems, modules, and pack assembly processes.
• Experience with process optimization methodologies such as Lean or Six Sigma.
• Ability to work independently and drive outcomes in a dynamic, project-based environment.
• Strong analytical, problem-solving, and communication skills.

Responsibilities

• Develop and optimize battery pack manufacturing processes, including module and pack assembly.
• Evaluate existing production workflows and identify opportunities to improve efficiency, cost, and product quality.
• Lead process validation, qualification, and continuous improvement initiatives.
• Collaborate with cross-functional teams including engineering, quality, and operations.
• Provide expertise in design for manufacturability (DFM) and scalability.
• Troubleshoot manufacturing and process-related issues and implement corrective actions.
• Create and maintain work instructions, SOPs, and process documentation.
• Support pilot builds and new product introduction (NPI) activities.

Skills

Battery pack manufacturing

Process development

Lean Six Sigma

Analytical skills

Communication skills

Independent work

Education

Bachelor’s degree in Mechanical, Electrical, Manufacturing Engineering

Tools

Lean Six Sigma tools

Job description

The PAC Group is seeking an experienced Battery Pack Process Development Consultant to support the development and optimization of manufacturing processes for advanced battery pack systems. This role will focus on improving production efficiency, quality, and scalability for battery pack assembly while collaborating with cross-functional engineering and manufacturing teams.

You will lead process design, validation, and continuous improvement initiatives, implement DFМ and scalability strategies,