Sr. Battery Manufacturing Engineer

AlleyCorp; San Jose (CA); On-site; USD 144,000 - 180,000; Full time

Job summary

AlleyCorp in San Jose, California, is seeking a Manufacturing Engineer with a BS or MS degree in engineering. The role involves designing and managing battery manufacturing processes for electric aircraft.

The ideal candidate has over 3 years of manufacturing experience, particularly in EV battery module production. Responsibilities include defining manufacturing processes, preparing budget plans, and optimizing production efficiency.

The company offers a competitive salary between $144,000 and $180,000, commensurate with skills and experience.

Qualifications

• 3+ years of manufacturing experience preferably in EV battery module/pack manufacturing.
• Strong hands-on experience with prototype and high-volume manufacturing.
• Experience working on CAPEX projects from concept through commissioning.

Responsibilities

• Oversee the manufacturing of Battery Module/Pack and associated components.
• Design and develop manufacturing lines for Battery Manufacturing.
• Prepare budget and project execution schedule for leadership reviews.

Skills

Manufacturing experience

Data analysis tools

Prototype and high-volume manufacturing

Statistical process control

Lean manufacturing

Process failure analysis

Education

BS or MS degree in engineering or a related field

Tools

Minitab

JMP

Python

CAD

PLM

MES

ERP software

Job description

Archer is an aerospace company based in San Jose, California building an all-electric vertical takeoff and landing aircraft with a mission to advance the benefits of sustainable air mobility. We are designing, manufacturing, and operating an all-electric aircraft that can carry four passengers while producing minimal noise.

Our sights are set high and our problems are hard, and we believe that diversity in the workplace is what makes us smarter, drives better insights, and will ultimately lift us all to success. We are dedicated to cultivating an equitable and inclusive environment that embraces our differences, and supports and celebrates all of our team members.

What you’ll do

• This role is within the High Voltage Power Systems Manufacturing Engineering team that oversees the manufacturing of Battery Module/Pack and associated components, responsible from prototype through series production.
• Design, develop and deploy manufacturing lines for Battery Manufacturing at Archer facilities
• Define build sequence, process flow steps, cycle time, layout, design for manufacturing and develop applicable manufacturing process solutions.
• Support process failure mode and analysis (PFMEA).
• Develop equipment specifications and work with suppliers through RFQ, PO, FAT/SAT, onsite installation, equipment validation/qualification and SOP.
• Prepare budget and project execution schedule and financial justification for leadership reviews.
• Develop factory acceptance testing plan and oversee the testing at various stages of the line development and launch.
• Drive process control, specifically in the areas of quality and equipment capability.
• Review and disposition quality notifications, including process non‑conformances, determining appropriate corrective and preventive actions. Participate in the material review board (MRB).
• Maintain and optimize manufacturing execution system (MES) configurations, including shop floor routings, process parameters, work instructions, and data collection protocols.
• Serve as process generalist and backup to process owners on production lines, providing technical support and troubleshooting during equipment downtime or process deviations.
• Identify and drive continuous improvement and cost reduction programs, optimize product flow and line efficiency by designing or improving tools, jigs, stations, work methods and ergonomics using the 5S methodology.
• Support operations on the shop floor, establish KPIs in order to drive performance management, identify trends and mitigate risks.

What you need

• BS or MS degree in engineering or a related field
• 3+ years of manufacturing experience preferably in EV battery module/pack manufacturing
• Strong hands‑on experience with prototype and high‑volume manufacturing
• Experience in working on CAPEX projects from concept through commissioning.
• Have a demonstrated track record of overall equipment effectiveness (OEE) improvement, preventative and predictive maintenance activities.
• Experience in statistical process control, GD&T, and lean manufacturing concepts
• Proficiency in data analysis tools (Minitab, JMP, Python, or similar statistical software)
• Experience with failure analysis techniques and root cause analysis methodologies (8D, 5‑Why, fishbone)
• Knowledge of safety standards (ANSI/RIA15.06, OSHA)
• Experience with CAD, PLM, MES, and ERP software.
• Understanding of PLCs, robots, motion control devices, vision systems and human machine safety devices.
• Ability to travel domestically and internationally

Bonus Qualifications

• Experience with thermoplastic part joining (e.g., ultrasonic welding)
• Understanding of aviation battery certification requirements (DO‑311A, DO‑160, RTCA standards)
• Experience with airworthiness requirements and aviation safety management systems
• Experience with aviation‑grade traceability and configuration management
• Experience with FAR 23, Part 21, FAA production certification

Please note that this job description is intended to provide a general overview of the position and does not include an exhaustive list of responsibilities and qualifications.

Archer is committed to attracting, retaining, and motivating talent that possesses the skills and leadership necessary to grow our business. We drive a pay‑for‑performance culture and reward performance that supports the company’s business strategy. For this position we are targeting a base pay between $144,000 and $180,000. Actual compensation offered will be determined by factors such as job‑related knowledge, skills, and experience.

Equal Employment Opportunity

Archer is proud to be an equal‑opportunity employer committed to diversity and inclusivity in the workplace. All aspects of employment are decided on the basis of merit, qualifications, and business needs. We do not discriminate based upon race, color, religion, sex, sexual orientation, age, national origin, disability status, protected veteran status, gender identity or any other characteristic protected by federal, state or local laws.

Archer is committed to working with and providing reasonable accommodations to job applicants with physical or mental disabilities, and those with sincerely held religious beliefs. Applicants who may require reasonable accommodation for any part of the application or hiring process should provide their name and contact information to Archer’s People Team at [e-mail]. Reasonable accommodations will be determined on a case‑by‑case basis.

Archer is unable to provide work visa sponsorship for this position at the present time.

Archer does not engage with external recruiting agencies or individual recruiters with whom it does not have a prior written agreement. Archer reserves the right to make use of any unsolicited resumes that it receives and bears no responsibility for payment of any fees asserted from the use of unsolicited resumes. If you are a recruiting agency or individual recruiter wishing to do business with Archer, please reach out to [e-mail]. All employment processes are managed by the Archer People Team.

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