Senior Process Engineer

UNAVAILABLE; Ann Arbor (MI); On-site; USD 90,000 - 130,000; Full time

Job summary

Navitas Systems LLC is seeking a Sr Manufacturing Engineer to drive process improvement and optimization on our high-volume Li-ion battery manufacturing line in Ann Arbor, MI.

The role emphasizes data-driven problem solving, SPC/ Six Sigma practices, and hands-on floor leadership to ensure safety, quality, and throughput in government/military oriented projects.

Qualifications

• Engineering degree in Mechanical or Manufacturing Engineering.
• 5+ years of experience in a production environment.
• Six Sigma Green Belt required; Black Belt preferred.
• Must be able to work on site in Ann Arbor, MI; US Citizen or Lawful Permanent Resident.

Responsibilities

• Oversee KPIs to monitor the efficiency and quality of the Li-ion battery manufacturing process.
• Lead continuous improvement initiatives using Lean Manufacturing, Six Sigma, and Kaizen.
• Lead root cause analysis for production issues and implement corrective actions to prevent recurrence.
• Oversee development of PFMEA, Work Instructions, OCAPs, and Control Plans for new processes.
• Lead and manage complex engineering projects from concept to implementation.
• Analyze production with statistical software (JMP or Minitab) to understand uptime, availability, and reliability metrics; investigate bottlenecks.
• Utilize data analysis and performance metrics to drive decisions on capacity, energy density, cycle life, and defect rates.
• Proficiency in Python, SQL and data visualization (Tableau, Power BI, Ignition).
• Collaborate with Production, Design Engineering, Quality Assurance, Safety & R&D, and Supply Chain to integrate new technologies.
• Partner with procurement to evaluate suppliers and materials; ensure regulatory and industry requirements for Li-ion manufacturing.
• Promote safety and continuous improvement; adhere to ITAR and military requirements.
• Must be present on site on a regular basis.

Skills

SPC

Six Sigma

Problem solving

Communication

Cross-functional teamwork

Education

Engineering degree in Mechanical Engineering or Manufacturing Engineering

Tools

Python

SQL

Tableau

Power BI

Ignition

Job description

Get to know East Penn!

Navitas Systems LLC, a leader in comprehensive energy storage solutions, was formed in 2011 with the merger of MicroSun Innovative Energy Storage Solutions and MicroSun Electronics, and the acquisition of lithium battery company A123 Systems’ Government Solutions Group. In 2019, East Penn Manufacturing, one of the world’s leading battery manufacturers, acquired majority interest in Navitas Systems. In SEVEN remarkable decades, East Penn has grown from a one-room shop with a product line of five automotive batteries to one of the world’s leading battery manufacturers with over 10,500 full-time employees, 515 product designs, operations around the world, and hundreds of awards for industry excellence.

At our Navitas facilities we engage in the research, design, development, and manufacture of advanced lithium cells and energy storage products and systems for both commercial customers and U.S. Government/military customers. We invest in our people, they are and always will be the heart of this company. Are you ready to join a family-owned enterprise committed to honoring the contributions of everyone? Then Navitas is the right place for you.

Overview

Navitas is seeking an experienced and highly motivated Sr Manufacturing Engineer to improve, optimize and solve complex problems on our Li-ion battery manufacturing line. An understanding of high volume manufacturing process improvement, analytical problem solving and complex data analysis is essential, ideally within the lithium-ion battery industry. This role is essential for driving the future of our battery production capabilities, ensuring operational excellence, and implementing innovative solutions to support company growth and product development in our growing markets.

Responsibilities

• Oversee the collection and interpretation of key performance indicators (KPIs) to monitor the efficiency and quality of the battery manufacturing process
• Implement and champion continuous improvement initiatives using methodologies such as Lean Manufacturing, Six Sigma, and Kaizen, with a focus on the specific challenges and demands of battery manufacturing.
• Lead root cause analysis for production issues related to battery cell quality, capacity degradation, and safety concerns, and implement corrective actions to prevent recurrence.
• Oversee the development of key documents for new processes, such as PFMEA, Work Instructions, OCAPs, Control Plans, etc.
• Lead and manage complex engineering projects related to lithium-ion battery manufacturing, from concept to implementation, ensuring alignment with cost, quality, and timeline objectives.
• Analyze production with statistical software (JMP or Minitab preferred) to understand manufacturing uptime, availability, and reliability metrics-yield, OEE, cycle time, quality and investigate bottlenecks to identify root cause and countermeasure to maximize throughput.
• Utilize data analysis and performance metrics to drive decisions that improve manufacturing performance, focusing on key indicators such as battery capacity, energy density, cycle life, and defect rates.
• Proficiency in Python, SQL and data visualization (i.e. Tableau, Power BI, Ignition)
• Collaborate with Production, Design Engineering, Quality Assurance, Safety & R&D, Supply Chain, and other teams to ensure seamless operations and integration of new technologies into the battery production process.
• Partner with the procurement team to evaluate suppliers and support the selection of new materials, raw materials, and equipment, ensuring they meet industry-specific requirements for lithium-ion battery manufacturing.
• Promote a culture of safety and continuous improvement, ensuring best practices are followed across all operations, particularly in relation to the handling of materials and processes that involve battery cells and electrolytes.
• Follow Company Policies and Procedures
• Physical presence on the job is essential and necessary
• Other duties as assigned by management

Qualifications

Education and Experience

• Engineering degree in Mechanical Engineering, Manufacturing Engineering, or a related field.
• 5 or more years of experience in a production environment and/or proven manufacturing development track record. Experience with high speed, high volume automated manufacturing equipment (Li-ion Cell Assembly, Packaging, Formation) a plus
• Six Sigma Green Belt required Black Belt preferred.
• Must be able to work 5 days a week on site in Ann Arbor, MI
• Must be US Citizen or Lawful Permanent Resident

Knowledge, Skills and Abilities

• Must be comfortable supporting US-military funded work and building products for military testing and use.
• Knowledge of lithium-ion battery production processes, battery formation such as charging, discharging, capacity, cycle life, and safety testing is preferred.
• Proven experience of going to the manufacturing floor to see and experience issues firsthand.
• Experience with high-volume manufacturing processes, such as automated assembly lines, robots, conveyors, PLCs, MES data collection systems, and testing preferably related to battery cell production.
• Proven experience working with cross-functional teams and managing complex projects in a manufacturing environment.
• Ability to work in a fast-paced, dynamic environment and adapt to changing priorities.
• Expertise in Statistical Process Control (SPC) and process capability (Six Sigma).
• Excellent problem-solving skills, with the ability to analyze complex manufacturing issues and implement practical solutions.
• Strong interpersonal and communication skills, with the ability to collaborate with stakeholders at all levels of the organization.

Disclaimer: This job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities, and activities may change at any time with or without notice. Must be comfortable doing work adhering to military and ITAR requirements.

East Penn Benefits

Navitas/East Penn offers excellent benefits:

• Competitive compensation
• Group health insurance that includes high quality medical, dental, vision and prescription coverage with a low employee premium
• Retirement Savings Plan with company match and a 3% employer contribution
• Paid company holidays and Paid Time Off (PTO)
• Employee assistance program
• Fitness Discounts
• Promotional opportunities

At Navitas/East Penn, our employees are our culture; our employees will always be the heart of the company. We are a private, family-owned enterprise committed to cultivating an atmosphere that honors the contributions of everyone. We want our employees to have long-term careers, and many do. More than 38% of our workforce has over a decade of service. Our open-door management policy, comprehensive benefits package, employee appreciation and recognition events, and career advancement opportunities are just some of the ways we show our employees how incredibly valued they are.

EOE/VEVRAA