Process Engineer - Jelly Roll Winding and Cell Assembly

PowerToFly; Greenville (SC); On-site; USD 90,000 - 130,000; Full time

Job summary

EnerSys is seeking a Specialist for Jelly Roll Winding & Cell Assembly to lead development and optimization of cylindrical Li‑ion winding and assembly processes. You will work with engineering, manufacturing, quality and automation teams to establish scalable processes from pilot lines to production.

The role emphasizes hands-on manufacturing excellence, data-driven improvement, and adherence to safety and quality standards across multiple cell formats.

Qualifications

• Bachelor’s degree in Mechanical, Production, Electrical, Manufacturing Engineering or Battery Technology.
• Three+ years in lithium-ion battery manufacturing focusing on cylindrical winding/assembly.
• Experience supporting equipment qualification, process validation, startup, and ramp-up.

Responsibilities

• Develop, optimize, and sustain jelly roll winding processes for cylindrical Li-ion cells (18650, 21700, 46xx).
• Control winding parameters: web tension, speed, alignment, overlap, separator handling, mandrel design.
• Support cell assembly: electrode prep, tab welding, insulation, jelly roll insertion, sealing, electrolyte filling.
• Analyze process performance and implement yield/throughput improvements.
• Investigate defects: alignment, separator damage, winding defects, contamination, burrs, internal shorts.
• Support FAT/SAT, commissioning, and production startup activities.
• Transfer processes from development to high-volume manufacturing with cross-functional teams.
• Create and maintain process docs: work instructions, PFMEA inputs, control plans.
• Apply Root Cause Analysis, 8D, SPC and continuous improvement techniques.
• Ensure compliance with dry-room standards, safety, quality systems, and contamination control.
• Participate in startup, commissioning, and manufacturing readiness for Gigafactory deployment.

Skills

Root Cause Analysis

8D Problem Solving

Statistical Process Control

Education

Bachelor’s degree in Mechanical Engineering

Related technical discipline

Six Sigma Green Belt or Black Belt

Tools

MES

SCADA

Manufacturing databases

Automated inspection systems

Production reporting tools

Job description

EnerSys is a global leader in stored energy solutions for industrial applications. We have over thirty manufacturing and assembly plants worldwide servicing over 10,000 customers in more than 100 countries. Worldwide headquarters are located in Reading, PA, USA with regional headquarters in Europe and Asia. We complement our extensive line of Motive Power and Energy Systems with a full range of integrated services and systems. With sales and service locations throughout the world, and over 100 years of battery experience, EnerSys is the power/full solution for stored DC power products.

Job Purpose

The Specialist, Jelly Roll Winding & Cell Assembly - Battery Cells is responsible for the development, optimization, industrialization, and support of cylindrical lithium-ion battery cell winding and assembly processes. This role focuses on jelly roll winding, electrode and separator handling, tab connection, can insertion, and related assembly operations that directly impact cell quality, safety, reliability, and manufacturing performance.
The position works closely with Engineering, Manufacturing, Quality, Maintenance, Automation, EHS, Product Development, and equipment suppliers to establish robust and scalable manufacturing processes from pilot operations through commercial production. The successful candidate combines strong technical expertise with a hands-on approach to manufacturing excellence and continuous improvement.

Essential Duties and Responsibilities

• Develop, optimize, and sustain jelly roll winding processes for cylindrical lithium-ion battery cell formats including 18650, 21700, and 46xx cells.
• Define, validate, and control critical winding parameters including web tension, winding speed, alignment, overlap, separator handling, mandrel design, and jelly roll geometry.
• Support cell assembly operations including electrode preparation, tab welding, insulation application, jelly roll insertion, beading, sealing, electrolyte filling interfaces, and pre-formation preparation activities.
• Analyze process performance and implement improvements to increase yield, throughput, process capability, operational efficiency, and product quality.
• Investigate and resolve manufacturing defects including alignment issues, separator damage, winding defects, dimensional deviations, contamination concerns, burr-related defects, and internal short risks.
• Support equipment selection, supplier technical reviews, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, qualification, and production startup activities.
• Collaborate with process engineering, product development, quality, maintenance, automation, and production teams to transfer processes from development and pilot operations to high-volume manufacturing.
• Develop and maintain process documentation including work instructions, process standards, training materials, PFMEA inputs, control plans, and operating procedures.
• Apply structured problem-solving methodologies including Root Cause Analysis, 8D, SPC, process capability analysis, and continuous improvement techniques.
• Ensure compliance with dry-room standards, safety requirements, quality systems, contamination control requirements, and battery manufacturing best practices.
• Participate in startup, commissioning, technology transfer, and manufacturing readiness activities supporting Gigafactory deployment and production ram

Qualifications

• Bachelor's degree in Mechanical Engineering, Production Engineering, Electrical Engineering, Manufacturing Engineering, Battery Technology, or a related technical discipline required. Technician or master craftsman qualifications with significant applicable experience may also be considered.
• Three (3) or more years of experience in lithium-ion battery manufacturing with emphasis on cylindrical cell winding and assembly operations preferred.
• Experience supporting equipment qualification, process validation, commissioning, startup, and production ramp-up activities preferred.
• Experience working in high-volume automated manufacturing environments preferred.
• Proficiency with Microsoft Office applications.
• Experience with MES, SCADA, manufacturing databases, automated inspection systems, and production reporting tools preferred.
• Experience with process monitoring and data analysis tools preferred.
• Six Sigma Green Belt or Black Belt certification preferred.
• Additional manufacturing, quality, or engineering certifications are beneficial.
• Domestic and international travel is required.

EnerSys provides equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

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