Process Engineer – Battery Separator Manufacturing & Optimization

NPAworldwide; Danville (VA); On-site; USD 100,000 - 120,000; Full time

Job summary

The Process Engineer is responsible for developing, optimizing, and supporting manufacturing processes within a lithium battery separator manufacturing environment.

The engineer owns assigned processes, uses engineering principles and data to improve safety, quality, yield, throughput, cost, and process stability. They work cross-functionally to troubleshoot challenges, establish process windows, implement improvements, support scale-up, and strengthen day-to-day manufacturing performance.

Qualifications

• BS degree in Mechanical, Industrial or Manufacturing Engineering.
• 37 years of process engineering experience in lithium battery manufacturing, roll-to-roll, web handling coating/converting, extrusion, plastics, chemical processing, or advanced manufacturing preferred.
• Hands-on experience with manufacturing troubleshooting, process optimization, production trials, and continuous improvement preferred.
• Knowledge of manufacturing processes, engineering principles, and structured problem solving.
• Working knowledge of SPC, DOE, PFMEA, Root Cause Analysis, process capability, and Lean/Six Sigma methodologies.
• Interpret data, equipment parameters, process trends, quality results to make sound decisions.
• Proficiency with Microsoft Office and manufacturing data analysis or historian tools.
• Ability to manage multiple projects and priorities in a fast-paced manufacturing environment.
• Strong written, verbal communication skills ability to work across technical and operational teams.
• Attention to detail, technical ownership, and commitment to safety and operational excellence.
• Travel as needed between plants.

Responsibilities

• Own and support assigned manufacturing processes, including mixing, coating, slitting, material handling, and related separator production operations.
• Analyze process performance, optimize operating parameters, improve safety, quality, yield, throughput, reliability, and cost.
• Troubleshoot process-related production issues, lead structured root-cause investigations, and implement sustainable corrective actions.
• Establish, document, maintain process windows, setup standards, and engineering procedures.
• Support production startup, process validation, equipment qualification readiness activities
• Lead and support continuous improvement projects focused on scrap reduction, yield improvement, cycle-time reduction, process capability, and equipment reliability.
• Apply engineering and statistical methods including Root Cause Analysis, SPC, PFMEA, DOE, and Six Sigma methodologies as appropriate.
• Identify and recommend process, equipment, controls, and material-handling modifications that improve manufacturing performance.
• Use process capability and trend data to identify recurring losses and prioritize improvement opportunities.
• Partner with R&D, Quality, and Operations to support new product introductions, process development, and manufacturing scale-up.
• Plan and execute pilot and production trials, including definition of trial objectives, data collection requirements, acceptance criteria, and technical conclusions.
• Evaluate new materials, technologies, equipment, and methods for production suitability.
• Translate development learnings into documented standards and repeatable production processes.
• Analyze manufacturing data, process trends, defects, and equipment parameters to support technical and operational decision-making.

Skills

Process optimization

Root Cause Analysis

Six Sigma

DOE

SPC

Lean

Education

BS degree in Mechanical, Industrial or Manufacturing Engineering

Tools

Microsoft Office

Manufacturing data historians

Job description

The Process Engineer is responsible for developing, optimizing, and supporting manufacturing processes within a lithium battery separator manufacturing environment.

The engineer owns assigned processes, uses engineering principles and data to improve safety, quality, yield, throughput, cost, and process stability. They work cross-functionally to troubleshoot challenges, establish process windows, implement improvements, support scale-up, and strengthen day-to-day manufacturing performance.