Battery Pack Specialist

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

Job Title: Battery Pack Specialist

Location: San Francisco City, CA

Client Facing: Yes

About PAC Group

At The PAC Group (PAC), we specialize in engineering consulting, program management, and operational excellence—delivering high-impact solutions in more than 20 countries. We’re proud to partner with the world’s leading companies in automotive, aerospace, industrial, and technology sectors, providing strategic guidance and hands-on execution that drive innovation and efficiency. Whether we’re launching advanced manufacturing systems, deploying digital simulation tools, or scaling global operations, PAC thrives at the intersection of technology, engineering, and problem-solving.

Joining PAC means joining a dynamic, fast-paced, and global team that values curiosity, collaboration, and continuous improvement.

Role Purpose

We are 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.

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.

Required Qualifications

• Bachelor’s degree in Mechanical, Electrical, Manufacturing Engineering, or a related field (or equivalent hands-on experience).
• 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.

Bonus Qualifications

• Experience working with EV battery systems or high-voltage applications.
• Familiarity with automation and advanced manufacturing technologies.
• Experience supporting production scaling and NPI programs.

The salary range for this position is dependent upon experience, education, and qualifications.

The salary range for this position is dependent upon experience, education, and qualifications.

Pay Range: $145,600 USD - $156,000 USD