Senior Manufacturing Engineer

Lehigh Heavy Forge Corporation; Commack (NY); On-site; USD 110,000 - 130,000; Full time

Benefits offered by this job

Generous Time Off

Comprehensive Benefits

401(k) Matching

Career Growth & Training

Innovative Culture

Job summary

Bren-Tronics, part of EnerSys, seeks a Senior Manufacturing Engineer to lead the transition of defense battery products from design to production. You will optimize assembly areas, drive cost reduction, and ensure strict MIL-STD/AS9100 compliance while mentoring production teams.

Ideal candidates bring 10+ years in manufacturing engineering with battery/defense experience and strong problem-solving skills to improve throughput and product quality.

Qualifications

• Bachelor-level engineering degree required in a relevant field.
• 10+ years in manufacturing engineering; 3+ years in battery or defense manufacturing preferred.
• Strong knowledge of battery technologies and DoD/defense manufacturing standards.

Responsibilities

• Lead transition of new defense battery products from design to production.
• Design and optimize battery assembly areas to meet DoD requirements and throughput goals.
• Drive continuous improvement to reduce costs, improve quality, and minimize scrap.
• Ensure compliance with MIL-STD, AS9100, IPC and related standards; develop SOPs and work instructions.
• Provide technical training to production teams and support audits and inspections.

Skills

Battery manufacturing

Root cause analysis

SPC

Lean Six Sigma

Engineering drawings

Cross-functional collaboration

Quality systems

Education

Bachelor's degree in Mechanical/Manufacturing/Electrical Engineering

Job description

EnerSys Advanced Systems (EAS) is a specialized division of EnerSys-a global leader in stored energy solutions for industrial applications. EAS focuses on cutting-edge energy solutions for the aerospace, defense, and medical industries. As we continue to grow, we're looking for individuals who share a passion for these industries and want to be part of an innovative, dynamic team.

Certain positions at EnerSys Advanced Systems require access to information or technology that is subject to the International Traffic in Arms Regulations (ITAR) and other U.S. government security regulations. Candidates for these positions should be a "U.S. Person" under ITAR (U.S. citizen, lawful permanent resident, or a refugee/asylee) and/or otherwise comply with ITAR requirements for access rights to be considered for a position.

What We Offer:

• Generous Time Off - 3+ weeks of paid time off, plus 11 paid holidays
• Comprehensive Benefits - Medical, dental, and vision coverage for employees and dependents at a discounted rate
• Financial & Career Growth - Life insurance, short-term disability, educational reimbursement, flexible spending accounts, and an employee stock purchase plan
• 401(k) Matching - 100% match at a 6% contribution level
• Innovative Culture - We value excellence, teamwork, and long-term relationships with stakeholders, colleagues, and customers. Through innovative technology and ongoing training, we invest in our employees' skills and career development.

At EAS, we don't just build batteries - we power systems and devices that protect not only individual citizens but communities across the world.

Compensation Range: $110,000 to $130,000 per year.

Compensation may vary based on applicant's work experience, education level, skill set.

Learn More About EAS

Job Purpose

The Senior Manufacturing Engineer at Bren-Tronics, part of EnerSys and manufacture of advanced power solutions, is a key technical leader responsible for developing, optimizing, and sustaining manufacturing processes for battery production in a defense environment. This role focuses on driving operational excellence through advanced failure analysis, continuous process improvement, and rigorous adherence to military-grade quality standards. The Senior Manufacturing Engineer will ensure efficient process transitions, maintain product integrity, reduce production costs, and uphold strict compliance with defense manufacturing protocols.

Essential Duties and Responsibilities

• Serve as the primary manufacturing representative on cross-functional engineering teams to lead and coordinate the smooth transition of new defense battery products from design to production.
• Design, organize, and continuously improve battery assembly areas to meet evolving product specifications, Department of Defense (DoD) requirements, and production throughput goals.
• Lead initiatives to streamline and optimize manufacturing workflows, enhancing product quality, reducing cycle time, minimizing scrap, and maximizing output.
• Define requirements for specialized production equipment, tooling, fixtures, and test setups specific to high-reliability, mission-critical battery manufacturing.
• Drive compliance with defense quality standards (e.g., MIL-STD, AS9100, IPC) across all manufacturing processes and work instructions.
• Develop and deliver technical training to production teams to ensure full compliance with documented procedures, quality standards, and engineering requirements.
• Manage manufacturing engineering and act as a subject matter expert for battery-specific manufacturing processes, materials, and technologies.
• Support audits, customer inspections, and quality assurance activities as needed to maintain defense manufacturing certifications.
• Determine the requirements for equipment, tools, fixtures and fulfill real-time production needs for our manufacture operations.
• Monitor rework and repair operations, consistently monitor and report yield issues, and regularly highlight significant findings.
• Conduct failure analysis, identify root causes, and pursue effective solutions to minimize in-process defects.
• Other duties as assigned.

Qualifications

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, or a related technical field.
• 10+ years of experience in manufacturing engineering, with 3+ years specifically in battery production, defense manufacturing, or other mission-critical industries strongly preferred.
• Strong knowledge of battery technologies, including cell assembly, electrode processing, electrolyte handling, welding, sealing, environmental testing, chargers and accessories.
• In-depth experience with root cause analysis methodologies (e.g., 5 Whys, Fishbone Diagram, FMEA) and corrective action implementation (CAPA).
• Hands-on experience with designing and optimizing manufacturing processes, production lines, tooling, and fixtures.
• Familiarity with defense manufacturing standards and compliance requirements (e.g., MIL-STD, AS9100, ITAR).
• Proficient in statistical process control (SPC), lean manufacturing, Six Sigma tools, and continuous improvement principles.
• Ability to read and interpret engineering drawings, schematics, specifications, and work instructions.
• Strong technical writing skills to create clear work instructions, reports, and standard operating procedures (SOPs).
• Excellent communication skills, with the ability to work collaboratively in cross-functional teams.

General Job Requirements

• Generic

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.

We use artificial intelligence to screen, assess and select applicants for open positions, including for the purposes of reviewing and ranking application materials and scoring answers to application questions. Accordingly, decisions about your application and eligibility for employment with EnerSys may be made based exclusively on the automated processing of the personal information that you submit in your application materials.

Nearest Major Market: Long Island

Nearest Secondary Market: New York CIty