Cell Assembly Process Engineer — DOE & Scale-Up

Our Next Energy; Michigan; On-site; USD 110,000 - 140,000; Full time

Job summary

Our Next Energy is seeking a hands-on Cell Assembly Process Development Engineer to lead development for dry cell assembly on lab, pilot, and production lines in Belleville, MI. You will partner with Product Development, Industrialization, Quality, and Manufacturing to ensure designs are manufacturable, safe, and economical.

The role requires 2–8 years in lithium-ion cell development, strong DOE/SPC and metrology knowledge, and experience transferring processes to high‑volume production.

Qualifications

• Bachelor’s or Master’s degree in Mechanical Engineering or a related field.
• 2–8 years of experience in lithium-ion cell development or manufacturing, including a minimum of 2 years directly related to cell assembly process engineering.
• Hands-on process experience with notching, stacking, hot pressing, cell assembly, hipot/short testing, leak testing, vacuum drying/baking, or other related processes.
• Understanding of how assembly defects such as burrs, particles, misalignment, and moisture drive internal shorts, self-discharge, and reliability failures.
• Strong command of DOE, SPC, statistical analysis (JMP, Minitab, or Python), PFMEA, control plans, and structured problem solving (8D).
• Experience with in-line and offline metrology, such as vision, X-ray/CT, hipot, leak testing, and Karl Fischer moisture analysis.
• Experience working in dry_room environments and with moisture-sensitive processes.
• Experience with LFP chemistry and large-format prismatic cells preferred.

Responsibilities

• Own process development for dry cell assembly: electrode notching, stacking, hot pressing, cell assembly, short (hipot/insulation) testing, leak testing, vacuum baking, and other related processes as applicable.
• Identify systemic bottlenecks and chronic yield losses across assembly processes using production data (MES, SPC, scrap Pareto, OEE), lead root‑cause analysis with 8D, DOE, and other structured problem‑solving methods, and implement and verify lasting solutions.
• Define critical process parameters and critical quality attributes (for example burrs, particles, electrode alignment and overhang, stack pressure, and residual moisture) and link them to cell performance, safety, and reliability.
• Design and run DOEs at lab, pilot, and production scale to establish robust process windows.
• Write process specifications, parameter sheets, and technology transfer packages, and provide process requirements to Industrialization for equipment specifications.
• Support FAT and SAT on process performance, confirming equipment can hold the process window and meet capability requirements, and support process validation (IQ/OQ/PQ).
• Develop in‑process inspection and test methods and acceptance criteria, including hipot/insulation, leak, alignment (vision and X‑ray), and post‑bake moisture.
• Partner with Quality to develop PFMEAs, control plans, SPC limits, and reaction plans for assembly processes.
• Provide design‑for‑manufacturing input to Cell Product Development and evaluate new materials, components, and design changes for manufacturability.
• Evaluate new assembly technologies and process improvements for future lines and line expansions.
• Support customer programs, including defense and aerospace programs, through process documentation, audits, technical reviews, and qualification builds.
• Contribute to building ONE’s intellectual property portfolio.

Skills

Root cause analysis

DOE

Statistical analysis

8D problem solving

Education

Bachelor’s or Master’s degree in Mechanical Engineering

Tools

JMP

Minitab

Python

Job description

Our Next Energy is seeking a hands-on Cell Assembly Process Development Engineer to lead development for dry cell assembly on lab, pilot, and production lines in Belleville, MI. You will partner with Product Development, Industrialization, Quality, and Manufacturing to ensure designs are manufacturable, safe, and economical.

The role requires 2–8 years in lithium-ion cell development, strong DOE/SPC and metrology knowledge, and experience transferring processes to high‑volume production.